Raymarine autopilot ST4000+ User guide

Distributed by
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.

ST4000+
Wheel & Tiller
Autopilots
Owner’s
Handbook
Document number: 81131-6
Date: August 2001

ii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
Autohelm,HSB(HighSpeedBus),SailPilot,SeaTalkandSportPilot
are registered trademarks of Raymarine Ltd.
Raymarine,AST (AdvancedSteeringTechnology),AutoAdapt,
AutoLearn, AutoRelease, AutoSeastate, AutoTack, AutoTrim,
FastTrim, GyroPlus,RayGyro,RayPilotand WindTrim are
trademarks of Raymarine Ltd.
Handbook contents © Raymarine Ltd 2001.

Preface iii
OR
Boat's electrical
distribution panel
Rudder position sensor
(optional fit for wheel pilot only)
ST4000+
control unit
Fluxgate compass
SeaTalk instrument
NMEA
instrument
or navigator
Tiller drive
Wheel drive
ST4000+ autopilot system layout
D5332-1

iv ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Preface v
Contents
About this handbook ...........................................................ix
Important Information .........................................................x
Warranty ......................................................................................x
Safety notices ..............................................................................x
EMC conformance .....................................................................xi
Handbook information ...............................................................xi
Chapter 1: Introduction ............................................................1
1.1 Features .....................................................................................1
1.2 Extendedsystems......................................................................2
Chapter 2: Basic Operation .......................................................3
2.1 Using thecontrol unit ................................................................ 4
Keyfunctions ............................................................................4
Displaylayout ...........................................................................5
2.2 Using Automode ......................................................................6
Engagingtheautopilot(Auto mode) .........................................6
Disengagingthe autopilot (Standby mode) .............................. 7
Changing course inAuto mode ................................................. 8
Dodgingobstacles inAutomode ..............................................8
Returning tothe previous lockedheading (LAST HDG) .........9
Automatictack(AutoTack) ....................................................10
Makingmajor course changes ................................................10
Gustingconditions .................................................................. 11
2.3 Adjustingautopilotperformance ............................................12
Changing theresponse level(AutoSeastate) ..........................12
Changing the rudder gain ........................................................ 13
2.4 Autopilot alarms .....................................................................14
Respondingto alarms ..............................................................14
2.5 Adjustingdisplayandkeypadlighting ...................................18
Chapter 3: Advanced Operation ............................................19
3.1 Using Trackmode ...................................................................20
SelectingTrackmode .............................................................20
ExitingTrackmode .................................................................22
Crosstrackerror ......................................................................22
Tidal streamcompensation .....................................................23
Waypoint arrivaland advance .................................................24
DodgesinTrackmode ............................................................25
SafetyinTrackmode ..............................................................25

vi ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
3.2 UsingWind Vanemode ..........................................................27
Selecting Wind Vane mode ..................................................... 27
ExitingWind Vanemode ........................................................28
Adjustingthe locked wind angle ............................................. 28
Returningto theprevious apparentwind angle
(LASTWND) .........................................................................28
Dodgesin Wind Vanemode ....................................................29
Wind shift alarm...................................................................... 29
Using AutoTack in Wind Vane mode ......................................30
Operatinghints forWindVane mode ......................................30
3.3 Displayingdata pages .............................................................31
Chapter 4: Maintenance & Fault Finding ..............................33
4.1 Fault finding ............................................................................34
4.2 Generalmaintenance .............................................................. 36
Wheeldrive .............................................................................36
Controlunit .............................................................................38
EMC advice ............................................................................39
4.3 Productsupport .......................................................................40
Softwareversion .....................................................................40
Chapter 5: Installing the ST4000+ ..........................................43
5.1 Planningtheinstallation .........................................................44
Toolsrequired .........................................................................44
EMC installationguidelines ................................................... 46
5.2 Controlunit .............................................................................48
Location ..................................................................................48
Mountingprocedure ...............................................................49
Cable connectors.....................................................................51
Powersupplyconnection ........................................................ 51
SeaTalk connections ...............................................................52
NMEAconnections ................................................................53
5.3 Fluxgatecompass ...................................................................55
Location ..................................................................................55
Mounting ................................................................................ 57
Connectingto thecontrol unit ................................................. 58
5.4 Tiller drive (tiller pilots only) .................................................. 59
Criticaldimensions .................................................................59
Basic installation .....................................................................60
Installation accessories ...........................................................61
Connectingto thecontrol unit ................................................. 68

Preface vii
5.5 Wheel drive(wheel pilots only) ..............................................70
Installationstages ....................................................................70
Drilling thespoke clamp holes ................................................71
Securing thewheel drive to the wheel .....................................74
Attaching thepedestal bracket ................................................ 75
Connectingto the control unit .................................................79
5.6 Rudderposition sensor (wheel pilotoption) ...........................81
Ensuring correct alignment .....................................................81
Securing the sensor tothe boat ................................................83
Attaching the sensor to the tiller arm .......................................83
Checkingalignment ................................................................84
Connectingto the control unit .................................................84
Chapter 6: Setting-up the ST4000+ ........................................85
6.1 Functionaltest .........................................................................86
Switchon ................................................................................86
Autopilot steeringdirection ....................................................86
Checkingconnections .............................................................88
6.2 Check rudder sensor operation(if fitted) ................................90
6.3 Initial sea trial ..........................................................................91
Overview ................................................................................91
Correctingthecompass deviation ..........................................92
Adjustingthe headingalignment ............................................95
Checking autopilot operation ..................................................95
Checking the rudder gain ........................................................96
6.4 Autopilot calibration techniques .............................................98
Step 1 - Switch onancillary equipment ................................... 98
Step 2 - Applyinitial settings ..................................................98
Step 3 - Adjust the rudder damping .........................................99
Step 4 - Adjust the rudder gain ................................................99
Step 5 - Adjust theAutoTrim setting .......................................99
Step 6 - Further adjustments ....................................................99
Chapter 7: Customizing the ST4000+ ..................................101
7.1 User setup ..............................................................................102
Compassdeviationcorrection(SWING COMPASS) ..........102
Deviation display (DEVIATION) ........................................102
Headingalignment(ALIGNHDG) ......................................102
Headingmode(HDGMAG/TRU) .......................................102
Bar selection (RUDD BAR/STEER BAR/NO BAR) ..........104
Data pages1-7 (DATAPAGE) .............................................. 104

viii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
7.2 Dealer setup .......................................................................... 106
Calibrationlock(CALLOCK) .............................................108
Pilottype(4000WHL/TILL) ...............................................108
Rudder gain (RUDD GAIN) ................................................. 108
Response level (RESPONSE) ..............................................108
Turn limit (TURN RATE) ..................................................... 108
Rudder alignment (ALIGN RUD) ........................................ 108
Rudder limit (RUD LIMIT) ..................................................109
Off course alarm (OFF COURSE) ........................................ 109
AutoTackangle(AUTOTACK) ...........................................109
AutoTrim (AUTOTRIM) ..................................................... 110
Drive type (DRIVE TYP) ..................................................... 110
Magnetic variation (VARIATION) ....................................... 110
AutoAdapt (AUTOADAPT) .................................................111
Latitude(LATITUDE) ...........................................................111
Rudder damping(RUDD DAMP) ........................................ 112
Cruise speed(CRUISESP) .................................................. 112
Specifications .................................................................... 113
Glossary .............................................................................. 115
Index ................................................................................... 117

Preface ix
About this handbook
Welcome to the handbook for the ST4000+ wheel and tiller
autopilot systems. This handbook contains two main parts:
Part 1: Using the ST4000+ Autopilot
Part 2: Installing the ST4000+ Autopilot
At the end of this handbook we have included product
specifications, a glossary and index, and templates for installing
different parts ofthe system.
Note:This handbook contains important informationabout
installing,usingand maintainingyournew Raymarine product.To
get thebest from the product, pleaseread this handbook thoroughly.
1Chapter 1: Introduction
Introduces the autopilot, its features and its use. page 1
2
Chapter 2: Basic Operation
Covers basic autopilot operation: using Auto mode,
interpreting alarms, adjusting autopilot performance and
changing the control unit lighting.
page 3
3Chapter 3: Advanced Operation
Explains how to use Track and Wind Vane modes, and
display data pages.
page 19
4
Chapter 4: Maintenance & Fault Finding
Provides general maintenance procedures and
information to help you resolve problems you may
encounter with the autopilot
page 33
5Chapter 5: Installing the ST4000+
Explains how to install your autopilot and its components. page 43
6
Chapter 6: Setting-up the ST4000+
Covers functional testing and dockside procedures after
installation, and initial sea trials.
page 85
7
Chapter 7: Customizing the ST4000+
Provides details on adjusting the autopilot settings to suit
your boat.
page 101

x ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
Important Information
Warranty
ToregisteryournewRaymarineproduct,pleasetakeafewminutesto
filloutthewarrantycard.Itisimportantthatyoucompletetheowner
informationandreturnthecardtoustoreceivefullwarrantybenefits.
Safety notices
WARNING: Product installation
Thisequipmentmustbe installedand operatedin accordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoor productperformance,personalinjury
and/ordamageto yourboat.
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbefore youmakeany
electrical connections.
WARNING: Calibration
Wesupplythisproductcalibratedtodefaultsettingsthatshould
providestableperformanceformostboats.To ensureoptimum
performanceonyourboat,youmustcompleteChapter6:
Setting-uptheST4000+beforeuse.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobeaccurateand
reliable, many factorscan affectitsperformance. As aresult,it
shouldonlybe usedasanaidtonavigationandshouldnever
replacecommon senseandnavigationaljudgement.Always
maintainapermanentwatchsoyoucanrespondtosituationsas
theydevelop.
YourRaymarineautopilotwilladd anew dimensiontoyourboating
enjoyment. However,it is the skipper’s responsibility to ensure the
safety ofthe boat at all times byfollowing these basicrules:
• Ensure that someone is present at thehelm AT ALL TIMES, to
take manual control in anemergency.

Preface xi
•Make sure that all membersof crew knowhow to disengage the
autopilot.
•Regularlycheckforotherboatsandanyobstaclestonavigation–
nomatterhowcleartheseamayappear,adangeroussituationcan
develop rapidly.
•Maintain anaccurate record of the boat’spositionby usingeither
anavigationaid or visualbearings.
•Maintaina continuousplotof yourboat’spositionona current
chart.Ensure that the locked autopilot headingwillsteer the boat
clear of all obstacles. Make proper allowance for tidal set –the
autopilotcannot.
•Evenwhenyourautopilotislockedontothe desired trackusinga
navigationaid,alwaysmaintainalogandmakeregularpositional
plots. Navigation signals can produce significant errors under
some circumstances and the autopilot will not be able to detect
these errors.
EMC conformance
All Raymarine equipment andaccessories are designed to thebest
industrystandards foruse in the recreational marine environment.
The design andmanufactureof Raymarine equipmentand
accessories conform to the appropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance is notcompromised.
Handbook information
To the best of our knowledge, the information inthis handbook was
correct when it wentto press.However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicyofcontinuousproductimprovementmay change
specifications without notice. As aresult, Raymarine cannot accept
liability for any differences between the product and the handbook.

xii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Part 1:
Using the
ST4000+
Part 1: Using the ST4000+

Part 1: Using the ST4000+

Chapter 1: Introduction 1
1 Introduction
Chapter 1: Introduction
1.1 Features
The Raymarine ST4000 Plus(ST4000+) isa SeaTalk®compatible
autopilot available in versions suitable for boats with either tiller or
wheel steering systems. This autopilot system willsteer yourboat to
a heading automatically, accurately and reliably.
The ST4000+ hasfourmain operating modes:
1. Standby: autopilot off (see page 7)
2. Auto:autopilot engaged andlockedonto aheading (see page 6)
3. Track: autopilot engagedand maintaining a trackbetween two
waypoints createdusinga navigation system (seepage 20)
4. Wind Vane:autopilotengagedandmaintainingacourserelative
to an apparent wind angle (see page 27)
The ST4000+ alsoprovidesthe following features:
•automatictackfacility(AutoTack)inAutoandWindVanemodes
•automatic compass deviation correction
•Northerly/Southerlyheading compensation
•automaticheading deadband –seastatecontrol
•waypointadvancefeature
•setupandcalibrationoptionstooptimizeperformanceonyourboat
D5460-1

2 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
1 Introduction
1.2 Extended systems
The ST4000+ is compatible with all other SeaTalk instruments.
You canconnect itto additionalfixedor handheld SeaTalk autopilot
control units located at secondary steeringand controlpositions
(see page 52).
Youcan alsousethe ST4000+ autopilot withany navigator
(GPS, Decca, Loran)or wind instrumentthat transmits data in the
internationally-accepted National Marine Electronics Association
(NMEA)0183 format.
The ST4000+ can display SeaTalk and NMEA instrument data in a
user-definedselectionof data pages.When you are using the
ST4000+torepeatinstrumentdata,itshowsa‘pop-up’pilotpagefor
5 seconds whenever you make a change in autopilot control.
The ST4000+can share all data transmittedfrom SeaTalk
instruments:
•it can usewind information froma SeaTalk wind instrument for
wind trim steering in Wind Vane mode without the need for a
separatevane
•itcanusetrackinformationfromaSeaTalknavigationinstrument
toprovide waypointcontrolin Trackmode
•itcanuseboatspeedfromaSeaTalkspeedinstrumenttooptimize
track-keepingperformance
Rudder position sensor (wheel drives only)
On wheel drive systemsyoucan fit arudderpositionsensor to
improve the wheel pilot’s performance (see page 81). Thisis
particularly advisable if yourboat’ssteeringsystem hassignificant
backlash,oryourequireoptimumperformance fromamechanicalor
cablesteeringsystem.Byusingtheinformationfromtherudderangle
sensor,theST4000+willalsobeabletoshowthetruerudderanglein
StandbyandAutomodes.
Note:YouMUSTaddarudderpositionsensoriffittingtheST4000+
toa hydraulicsteeringsystem.

Chapter 2: Basic Operation 3
2 Basic Operation
Chapter 2: Basic Operation
Thesectionsinthischapterexplainhowtousethebasicfunctionson
yourautopilot:
CAUTION: Important note for wheel drive systems
Aftereachtrip,flushinsidethedriveunitbyinsertingahosepipe
inthefreeslotonthebackcover.Thiswillpreventanybuild-upof
salton thedrive ring andbearings.
2.1 Using the control unit
Summarizes the key functions and screen layout on the
ST4000+ control unit.
page 4
2.2 Using Auto mode
Provides instructions for engaging/disengaging the
autopilot and using Auto mode.
page 6
2.3 Adjusting autopilot performance
Making temporary adjustments to response level and
rudder gain to enhance autopilot performance.
page 12
2.4 Autopilot alarms
Describes how to recognize and respond to the
autopilot alarms.
page 14
2.5 Adjusting display and keypad lighting
Explains how to change the lighting on the control unit
display and keypad.
page 18

4 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook
2 Basic Operation
2.1 Using the control unit
Key functions
•The autopilot always powersup in Standby mode.
•You control the autopilot by pressing the buttons on the control
unit. The control unit confirms each button presswith a short
beep.
•You accessthe main functionsby pressing a single key:
•for example, whenthe autopilotis operating you can make
coursechanges using the -1,+1,-10 and+10 keys
•To access other functions you need to press two keys together:
•for example, whenthe autopilotis operating you makean
AutoTack to port by pressing the -1 and-10 keys together
•You can return to manual steering atany time bypressing
standby and disengaging theautopilot (see page 7).
TRACK
Press for Track
mode from Auto
Press to accept
waypoint advance
Press for 1 second
to skip waypoint
AUTO
Press for Auto mode
Press for 1 second
for Last Heading
Press again to
accept Last Heading
DISP
Press for
Data Page
Press for 1 second
for lamp control
STANDBY
Press for
Standby mode
Press and hold for
User and Dealer
setup modes
Course change keys
Port 1˚ Starboard 1˚
Port 10˚ Starboard 10˚
STANDBY plus AUTO
Press for Wind Vane mode
Press for 1 second for Last Wind
Press again to accept Last Wind
-1 plus +1
Press for Response level
Press for 1 second
for Rudder Gain +1 plus +10
Press together
for AutoTack
to starboard
-1 plus -10
Press together
for AutoTack
to port
D3447-2

Chapter 2: Basic Operation 5
2 Basic Operation
Display layout
The ST4000+ autopilot display providesthe following information:
•If the display shows nodistance unit all distancesare in
kilometres (Km), otherwise distances are in nautical miles (nm)
or statute/land miles (SM).
•The bar graph at the bottom of the screen is normally a
direction-to-steer indicator (you can change this in User setup,
see page 104).Theinformationdisplayedonthebargraphvaries
according to theautopilot mode:
Autopilot mode Information displayed on bar graph
Standby Rudder bar (only if a rudder position sensor is fitted)
Auto Heading error bar
Track Cross track error (XTE) bar, in 0.02 nm increments
Wind Vane Wind angle error bar
Rudder or Steer direction indicator
(bar graph in 2˚increments)
Port and Starboard
direction-to-steer
indicators
Autopilot mode
indicators
Response level indicator
Distance units
Heading indicators
Variable text region (up to 9 characters/digits)
D3316-2
Calibration mode
indicator