Raymarine EV-100 User manual

Evolution
Wheel drive
autopilot
Installation
Instructions
English
Date: 05-2017
Document number: 87287-2
© 2017Raymarine UK Limited

81131_8.book Page 118 Thursday, October 7, 2004 11:03 AM

Important Information
This handbook contains important information about installing,
using and maintaining your new Raymarine product. To get the best
from the product, please read this handbook thoroughly.
Warranty
To register your new Raymarine product, please take a few minutes to
register on the website at www.raymarine.com/warranty
Safety notices
WARNING: Product installation
This equipment must be installed and operated 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.
WARNING: Electrical safety
Make sure the power supply is switched off before you make any
electrical connections.
WARNING: Calibration
We supply this product calibrated to default settings that should
provide stable performance for most boats. To ensure optimum
performance on your boat, you must complete the procedures
detailed in the Commissioning section of the handbook for the
relevant Autopilot controller.
WARNING: Navigation aid
Although we have designed this product to be accurate and
reliable, many factors can affect its performance. As a result, it
should only be used as an aid to navigation and should never
replace common sense and navigational judgement. Always
maintain a permanent watch so you can respond to situations as
they develop.
81131_8.book Page vii Thursday, October 7, 2004 11:03 AM

Your Raymarine autopilot will add a new dimension to your boating
enjoyment. However, it is the skipper’s responsibility to ensure the
safety of the boat 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 members of crew know how to disengage the
autopilot.
• Regularly check for other boats and any obstacles to navigation –
no matter how clear the sea may appear, a dangerous situation can
develop rapidly.
• Maintain an accurate record of the boat’s position by using either
a navigation aid or visual bearings.
• Maintain a continuous plot of your boat’s position on a current
chart. Ensure that the locked autopilot heading will steer the boat
clear of all obstacles. Make proper allowance for tidal set – the
autopilot cannot.
• Even when your autopilot is locked onto the desired track using a
navigation aid, always maintain a log and make regular positional
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 and accessories are designed to the best
industry standards for use in the recreational marine environment.
The design and manufacture of Raymarine equipment and
accessories conform to the appropriate Electromagnetic
Compatibility (EMC) standards, but correct installation is required to
ensure that performance is not compromised.
Handbook information
To the best of our knowledge, the information in this handbook was
correct when it went to press. However, Raymarine cannot accept
liability for any inaccuracies or omissions it may contain. In addition,
our policy of continuous product improvement may change
specifications without notice. As a result, Raymarine cannot accept
liability for any differences between the product and the handbook.
81131_8.book Page viii Thursday, October 7, 2004 11:03 AM

EMC installation guidelines
All Raymarine equipment and accessories are designed to the best
industry standards for use in the recreational marine environment.
Their design and manufacture 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 will perform
under all conditions, it is important to understand what factors could
affect the operation of the product.
81131_8.book Page 36 Thursday, October 7, 2004 11:03 AM
The guidelines given here describe the conditions for optimum EMC
performance, but it is recognized that it may not be possible to meet
all of these conditions in all situations. To ensure the best possible
conditions for EMC performance within the constraints imposed by
any location, always ensure the maximum separation possible
between different items of electrical equipment.
For optimum EMC performance, it is recommended that wherever
possible:
• Raymarine equipment and cables connected to it are:
• At least 3 ft (1 m) from any equipment transmitting or cables
carrying radio signals e.g. VHF radios, cables and antennas.
In the case of SSB radios, the distance should be increased to
7ft(2m).
• More than 7 ft (2 m) from the path of a radar beam. A radar
beam can normally be assumed to spread 20 degrees above
and below the radiating element.
• The equipment is supplied from a separate battery from that used
for engine start. Voltage drops below 10 V, and starter motor
transients, can cause the equipment to reset. This will not damage
the equipment, but may cause the loss of some information and
may change the operating mode.
• Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performance and must be avoided
unless doing so is detailed in the installation manual.
• If a suppression ferrite is attached to a cable, this ferrite should not
be removed. If the ferrite needs to be removed during installation
it must be reassembled in the same position.

81131_8.book Page 37 Thursday, October 7, 2004 11:03 AM

Parts supplied
D5439-4
Wheel drive parts
Clamp screw,
M5 x 16 mm (x6)
Wheel drive
Pedestal bracket
Spoke clamp (x3)
16 mm spoke
clamp insert (x3)
12 mm spoke
clamp insert (x3)
6 mm
drill bit
3 mm
allen key
4 mm
drill bit
Power cable
4.5 m (15 ft)
Bracket screw,
No 10 x 3/4 in (x4)
Cable clip
and screw,
No 6 x 1/2 in
Optional: Bulkhead/box pedestal fitting kit E15017 (if required)
Rudder position sensor
(if supplied)
Tiller pin
Ball joint (x2)
Stud
Nut (x2)
No 8 x ¾ inch
Countersunk head screw (x2)
No 8 x ¾ inch
Pan head screw (x3)
5

6
D5370-2
361 mm (14.2 in) diameter
228 mm (9.0 in) diameter
135 mm
(5.3 in)
171 mm (6.7 in)
[plus 60 mm (2.4 in)
for cable clearance]
motor tube:
48 mm (1.9 in)
diameter
Wheel drive dimensions 28 mm
(1.1 in)
152 mm
(6.0 in) 154 mm
(6.1 in)
81131_8.book Page 104 Thursday, October 7, 2004 11:03 AM
Dimensions

7
Wheel drive (wheel pilots only)
The Raymarine wheel drive will fit 3, 4, 5, 6, 7 or 8 spoke wheels. It is
designed to operate with steering systems with between 1 to 3.5 turns
lock to lock.
Installation stages
Installing the wheel drive involves four stages:
1. Drilling the spoke clamp holes in the front cover.
2. Securing the wheel drive to the wheel.
3. Attaching the pedestal bracket.
4. Connecting the drive to the control unit.
Clamp screw,
M5 x 16 mm (x6)
Wheel drive
front cover
Pre-drilled spoke
clamp holes (x2)
Bracket screw,
No 10 x 3/4 inch (x4)
Clutch lever
Motor tube
Cable socket
Cable plug
Bracket pin
Pedestal
bracket
D5402-2
Spoke clamp (x3) Clamp insert (x3)
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8
Drilling the spoke clamp holes
1. Remove the wheel drive front cover:
• the front cover is held onto the wheel drive by three ‘push-fit’
posts which sit in three sockets on the drive ring
• to remove the cover, hold the motor in one hand and use your
other hand to pull the cover up and away from the drive unit
(as shown below)
2. Identify the appropriate spoke clamp holes for your wheel. With
the arrow at the top, refer to the following diagrams:
• the holes are numbered inside the cover (e.g. if you have a 5
spoke wheel, you need to drill the 4 locations marked with ‘5’)
• mark the appropriate spoke clamp holes and check them by
holding the cover against your wheel
D5403-1
D5348-1a
5 spokes 7 spokes
Top 2 spoke clamp holes
are pre-drilled
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9
Note: The wheel drive is designed to work with 3 spoke clamps on
4 or 8 spoke wheels. For cosmetic reasons, however, you may want to
fit an extra spoke clamp to the fourth spoke. Raymarine dealers can
supply an extra spoke clamp (part number A18089).
3. Drill the appropriate spoke clamp holes using the larger of the
supplied drill bits (6.0 mm or 1/4in):
• drill from the inside, placing a piece of scrap wood under the
cover to produce a clean exit hole
• you will need to drill 4 new holes so the cover has 6 holes in
total (2 for each spoke clamp)
Note: The spoke clamps will cover these exit holes, so they will not be
visible when the wheel drive is installed.
D5348-1b
3 or 6 spokes 4 or 8 spokes
Top 2 spoke clamp holes
are pre-drilled
Piece of scrap wood
D5347-1
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10
4. Align the cover with the wheel drive:
• the two pre-drilled holes (marked with an arrow) must line up
with their matching pair of threaded inserts on the drive ring
(also marked with an arrow)
• make sure that the other spoke clamp holes align with their
threaded inserts
Note: The cover will only fit back onto the wheel drive when you have
aligned the two parts correctly.
5. Fit the cover back onto the wheel drive:
• press the cover in the three places shown on the diagram
below to push each of the posts back into its locating socket
Note: This step is easier with the clutch engaged.
Pre-drilled holes
(marked with arrow) Pair of threaded inserts
(marked with arrow)
Drive ring
Front cover Drive unit D5404-1
D5405-1
TOP
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11
Securing the wheel drive to the wheel
1. Remove the wheel from the pedestal and place it on top of the
drive unit, with the front of the wheel and drive both facing up.
2. Using the wheel drive template at the end of this book, select the
correct set of spoke clamp inserts for your wheel:
• measure the spoke diameter at a distance of about 135 mm
(5.3 in) from the center of the wheel
• select the appropriate set of inserts: the wheel drive is supplied
with 2 sets of 3 inserts suitable for 12 mm (1/2in) and 16 mm
(5/8in) diameter spokes – each insert is marked with its size
3. Fit the first spoke clamp:
• lubricate the spoke with washing-up liquid – so you can slide
the spoke clamp along the spoke to adjust its position
• place the insert on the spoke about 135 mm (5.3 in) from the
wheel center – this distance is not critical as the wheel drive
will self-center as you fit all 3 spoke clamps
• place the spoke clamp onto the insert, making sure that you
have correctly located the clamp insert in the clamp
• locate 2 of the clamp screws (M5 x 16 mm allen-head screws)
•lightly tighten the screws using the 3 mm allen key (supplied)
4. Repeat step 3 to fit the other 2 spoke clamps. As you fit each one,
adjust the position of the wheel relative to the wheel drive so the
holes in the clamp line up with the holes in the cover. As you do
this, the wheel drive will self-center on the wheel.
5. After fitting all 3 spoke clamps, fully tighten the screws.
D5406-1
135 mm (5.3 in)
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12
Attaching the pedestal bracket
Note: If your wheel is bulkhead or box pedestal mounted, you will
need to obtain a bulkhead fitting kit (part number E15017) from your
Raymarine dealer. Fitting instructions are supplied with the kit.
Motor tube location
Depending on the design of your pedestal and any surrounding
obstructions, you can mount the wheel drive in one of two ways:
•Slot 1 installation: the standard position uses slot 1 on the back of
the wheel drive (the slot closest to the motor tube) so the motor
tube is at the bottom to the right of the pedestal
•Slot 2 installation: the alternative installation uses slot 2 to
position the motor tube at the top to the left of the pedestal
Select the appropriate slot so the motor tube is clear of obstructions.
CAUTION:
If you use slot 2 and you have a pedestal-mounted compass, the
drive motor may affect compass readings.

Slot 2 installation:
  
 
Slot 1 installation:
  
 
   
81131_8.book Page 66 Thursday, October 7, 2004 11:03 AM

13
Pedestal bracket – length and position
Note: If you are replacing an existing wheel drive, you need to:
remove the old pedestal bracket, cut the new bracket pin to the
correct length (see steps 2and 3 below), then secure it inthe standard
orientation using the existing pedestal holes.
1. Fit the wheel onto the pedestal, tighten the wheel nut to hold the
wheel in place, and engage the wheel drive’s clutch:
• if possible, lock the wheel in position with the appropriate slot
centered at the bottom of the wheel
• otherwise, you will find it useful to have an assistant to hold
the wheel in position so you can locate the bracket correctly
2. Measure dimension A – the distance between the front of the
pedestal and the rear edge of the drive’s front cover (see diagram):
• you may find it easiest to hold the bracket below the wheel
drive and mark dimension A directly on the pin
Note: If the wheel is bent or not running true, dimension A will
change with the wheel position. Measure the smallest distance.
3. Use a hacksaw to cut the pin 10 mm (0.4 in) LONGER than
dimension A. Remove any sharp edges at the cut end with
sandpaper or a file.
4. Place the pin end in slot 1 or 2 (as required):
• to do this you may need to loosen the wheel nut so you can
slide the wheel forward slightly, place the pin end in the slot,
return the wheel to its normal position and re-tighten the
wheel nut

 
 

81131_8.book Page 67 Thursday, October 7, 2004 11:03 AM

14
Note: You can install the pedestal bracket either way up. In the
standard orientation the pin is at the bottom (below the mounting
holes – see diagram). If obstructions on the pedestal prevent you
from using the standard orientation, you can install the bracket so the
pin is at the top (above the mounting holes).
5. Making sure the slot is central at the bottom of the drive unit
(6 o’clock position) and the pin is in the middle of the slot,
carefully draw around the bracket.
6. Remove the wheel, then hold the bracket on the pedestal in the
location you have marked.
7. Check the position and alignment of the pedestal bracket:
• the bracket pin should be 154 mm (6.1 in) below the pedestal
spindle (see the following diagram)
• the bracket pin should be aligned so it is directly below the
pedestal spindle (see the following diagram)

   

D5345-2
81131_8.book Page 68 Thursday, October 7, 2004 11:03 AM

15
8. When the pedestal bracket is correctly positioned and aligned,
mark around the inside of the slots, then remove the bracket.
9. Use a center-punch to mark the center of each slot, then use the
smaller supplied drill bit to drill a 4.0 mm (5/32 in) diameter hole.
Note: Drill at right angles to the pedestal surface.
10. Hold the bracket in place then lightly tighten the four cross-head
screws (No 10 x 3/4in). As you do this, make sure the bracket is
correctly aligned.
11. Replace the wheel, making sure that you locate the pin in the
correct slot (slot 1 or slot 2).
12. Turn the wheel with the clutch off to check that the bracket is
correctly positioned and aligned.
D5346-2
154 mm
(6.1 in)
D5344-2
81131_8.book Page 69 Thursday, October 7, 2004 11:03 AM

16
Note: If the wheel is bent or the wheel drive is off center, the pin will
move up and down in the back plate slot. As long as the pin does not
hit the top or bottom of the slot, this pin movement will not affect the
drive unit’s performance.
13. When you have checked alignment, fully tighten all four screws.
Connecting to the control unit (ACU)
When you have attached the pedestal bracket, you need to connect the
wheel drive to the control unit. The drive unit is supplied with 4.5 m
(15 ft) of 2-core cable with a waterproof socket at one end.
1. Connect the socket to the plug on the wheel drive’s motor tube:
• remove the socket cover
• pull back the plug cover
• align the locking ring, plug and socket as shown below
• push the plug firmly into the socket
• turn the locking ring 90° clockwise
• make the connection waterproof by pulling the plug cover
across so it protects the plug and socket
Note: To remove the plug, pull back the cover and turn the locking
ring 90° anti-clockwise. If you disconnect the socket for any reason,
always use the attached rubber cover to protect the socket.
D5409-1
CablePlug cover
(pulled back)
Locking ring
Contact
Socket
Socket coverMotor tube
Plug
81131_8.book Page 70 Thursday, October 7, 2004 11:03 AM

17
2. Route the cable through the pedestal (or guard rail) and back to the
control unit:
• if the pedestal has a cable duct, use this for the drive cable to
make sure that it cannot foul the steering mechanism
3. Run the drive cable back to the control unit and connect the two
cores to the Drive terminals as shown.
D5338-1
81131_8.book Page 71 Thursday, October 7, 2004 11:03 AM

ACU (control unit) connection
A B+
_
MOTOR
POWER
D13589-1
To the
ACU
Wheel Drive cable ACU
Blue Brown
NOTE: You can use the autopilot control head to change the Motor phase:
MENU > Setup > Autopilot Calibration > Drive Settings > Motor Phasing
18