Raymarine ST4000 Plus 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 Pl us
Wheel & Tiller
Aut opilot s
Ow ner ’ s
Handbook
Document number : 81131_4
Dat e: 18t h Apr i l 1999

2Titleofhandbook

Pr ef ace i
Boat's Electrical
Distribution Panel
Rudder Reference Unit
(optional fit for wheel pilot only)
ST4000 Plus
Control Head
Fluxgate Compass SeaTalk Instruments
Tiller Pilot Actuator
Wheel Pilot Actuator
D3456-1

ii ST4000PlusWheel &TillerAutopilotsOwner’sHandbook
Raytheon Electronics, as part of its commitment to continuous improvement and updating,
reserve the right to make changes, without prior notice, to the equipment, equipment
specifications, and the instructions contained within this handbook.
To the best of our knowledge, the information contained within this handbook was correct
as it went to press.
A great deal of care has been taken to ensure that this handbook is as accurate as possible.
However, liability cannot be accepted for inaccuracies or omissions.
Autohelm and SeaTalk are registered trademarks of Raytheon Electronics of Raytheon
Electronics
WindTrim, AutoTack, AutoTrim, Auto Seastate, AutoAdapt and Auto Dockside are
trademarks
Copyright © Raytheon Electronics 1996

Pr ef ace iii
Pref ace
This handbook contains information on the operation and installation
of your new equipment. In order to obtain the best performance from
your autopilot, please read this handbook thoroughly.
How t his handbook is organised
This handbook is divided into the following chapters:
Chapter 1: Introduces the autopilot, its features and its use.
Chapter 2: Covers basic autopilot operation.
Chapter 3: Explains how to use Track and Vane (WindTrim) modes
and adjust autopilot performance, and summarises the ST4000 Plus
alarms.
Chapter 4: Explains how to use the CodeLock security feature.
Chapter 5: Provides details on how to make adjustments to customise
the autopilot to your particular vessel.
Chapter 6: Explains how to install your autopilot and its components.
Chapter 7: Covers functional testing and dockside procedures after
installation, and intial sea trials.
Chapter 8: Provides general maintenance procedures.
Chapter 9: Provides information to help you resolve any problems you
may encounter with your autopilot.
An index is included at the end of this handbook, followed by templates
for the installation of the control head, SeaTalk deck connector and
rudder reference transducer.
War rant y
To verify the ownership of your new autopilot, please take a few
minutes to complete the warranty card. It is important that you
complete the owner information and return the card to the factory to
receive full warranty benefits.

iv ST4000PlusWheel &Tiller AutopilotsOwner’sHandbook
Saf et y i nf or ma t i on
Passage making under autopilot control is an enjoyable experience that
can, if you are not careful, lead to the relaxation of the permanent
watch. A permanent watch MUST be maintained no matter how clear
the sea may appear to be.
Remember, a large ship can travel two miles in five minutes – just the
time it takes to make a cup of coffee.
The following rules should always be observed:
•Maintainapermanentwatchandregularlycheckallaroundforother
vessels and obstacles to navigation – no matter how clear the sea
may appear a dangerous situation can develop rapidly.
•Maintainanaccuraterecordofthevessel’spositioneitherbyuseof
a radio navigation receiver or visual bearings.
•Maintainacontinuousplotofpositiononacurrentchart.Ensurethe
locked autopilot heading steers you clear of all obstacles. Make
proper allowance for Tidal Set – the autopilot cannot!
•EvenwhenyourautopilotislockedontothedesiredTrackusinga
radio navigation receiver, always maintain a log and make regular
positional plots. Radio navigation signals can produce significant
errors under some circumstances and the autopilot cannot detect this
situation.
•Makesurethatallmembersofcrewarefamiliarwiththeprocedures
to disengage the autopilot.
Your Raytheon autopilot will add a new dimension to your boating
enjoyment. However, it is the responsibility of the skipper to ensure the
safety of the vessel at all times by careful observance of these basic
rules.
EM C Conf or ma nce
All Raytheon equipment and accessories are designed to the best
industry standards for use in the leisure 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.

Pr ef ace v
Contents
Preface ................................................................................... iii
How this handbook is organised ...................................... iii
Warranty ........................................................................... iii
Safety information ............................................................ iv
EMC Conformance .......................................................... iv
Chapter 1: Introduction ......................................................... 1
1.1 Overview ..................................................................... 1
1.2 Extended systems ........................................................ 2
1.3 Specification ............................................................... 2
Chapter 2: Basic Operation ................................................... 3
2.1 Key functions .............................................................. 3
2.2 Display layout ............................................................. 4
2.3 Using Auto mode ........................................................ 5
Engaging the autopilot (Auto) ..................................... 5
Disengaging the autopilot (Standby) to return to hand
steering ........................................................................ 6
Changing course in Auto mode ................................... 6
Dodging obstacles in Auto mode ................................ 7
Returning to the previous locked heading ................... 7
Automatic tack (AutoTack) ......................................... 8
AutoTack to starboard ........................................... 8
AutoTack to port .................................................... 9
Off course alarm .......................................................... 9
Operating hints .......................................................... 10
Making major course changes ............................. 10
Course changes under autopilot control .............. 10
Gusty conditions .................................................. 11

vi ST4000 PlusWheel & Tiller AutopilotsOwner’sHandbook
2.4 Display and keypad illumination .............................. 11
2.5 Data pages ................................................................. 12
Chapter 3:Advanced Operation ......................................... 15
3.1 Operation in track mode............................................ 15
Initiating track mode ................................................. 15
Automatic acquisition .......................................... 16
Manual acquisition .............................................. 17
Cross track error ........................................................ 18
Tidal stream compensation ........................................ 18
Waypoint arrival and advance ................................... 19
Arrival .................................................................. 19
Skipping a waypoint – SeaTalk navigators only .. 20
Advance ............................................................... 20
Dodges....................................................................... 20
Initiating a dodge manoeuvre .............................. 20
Cancelling a dodge manoeuvre ............................ 20
Safety ......................................................................... 21
Position confirmation at the start of a passage .... 21
Verifying computed positions .............................. 21
Plot frequency ...................................................... 21
Setting waypoints ................................................. 21
General ................................................................ 21
3.2 Operation in Vane mode (WindTrim) ....................... 21
Selecting Vane mode ................................................. 22
Adjusting the locked wind angle ............................... 22
Returning to the previous apparent wind angle ......... 23
Dodges....................................................................... 23
Wind shift alarm ........................................................ 24
Using AutoTack in Vane mode .................................. 24
Operating hints .......................................................... 25

Pr ef ace vii
3.3 Adjusting autopilot performance .............................. 26
Changing the response level (AutoSeastate) ............. 26
Changing the rudder gain .......................................... 27
3.4 Alarms ....................................................................... 27
Chapter 4: CodeLock ............................................................ 31
4.1 CodeLock modes ...................................................... 31
4.2 Setting up CodeLock ................................................. 31
Initial setup ................................................................ 31
Changing the code or master unit .............................. 33
4.3 Entering your code (Manual mode only) .................. 33
4.4 Code number problems ............................................. 34
Chapter 5: Customising the ST4000 Plus........................... 35
5.1 User Setup ................................................................. 35
Compass deviation correction ................................... 37
Deviation display ....................................................... 37
Heading alignment .................................................... 37
Heading mode ........................................................... 37
Bar selection .............................................................. 37
Dockside rudder cal................................................... 38
Data pages ................................................................. 38
5.2 Dealer Setup .............................................................. 40
Calibration lock ......................................................... 42
Pilot type ................................................................... 42
Rudder gain ............................................................... 43
Response ................................................................... 43
Turn limit ................................................................... 43
Align rudder (Rudder Offset) .................................... 43
Off course alarm ........................................................ 43
AutoTack angle ......................................................... 44

viii ST4 0 0 0 Pl u s Wh eel & Ti l l er A u t o p i l o t s Ow n e r ’ s Han d b o o k
Autotrim .................................................................... 44
Drive type .................................................................. 45
Variation .................................................................... 45
AutoAdapt ................................................................. 45
Latitude ..................................................................... 46
Rudder damping ........................................................ 46
Cruise speed .............................................................. 46
Chapter 6: Installation ........................................................ 47
6.1 Planning the installation ............................................ 47
EMC installation guidelines ...................................... 47
Suppression ferrites ............................................. 48
Connections to other equipment .......................... 48
Cabling ...................................................................... 48
6.2 Control head .............................................................. 49
Siting ......................................................................... 49
Mounting procedure .................................................. 49
Cable connectors ....................................................... 50
Power supply connection ........................................... 51
Connections to SeaTalk ............................................. 52
SeaTalk cables ..................................................... 52
Typical SeaTalk cabling ...................................... 52
Cable types .......................................................... 53
6.3 Fluxgate compass ...................................................... 53
Mounting location ..................................................... 53
Mounting location for steel-hulled vessels ................ 54
Cabling ...................................................................... 55
6.4 Rudder reference transducer ..................................... 56
Mounting position ..................................................... 56
Control dimensions.................................................... 57

Pr ef ace ix
Installing the rudder reference transducer ................. 57
Cabling................................................................. 58
6.5 Wheel drive actuator ................................................. 58
General information .................................................. 58
Clamp selection ......................................................... 59
Fitting to metal wheels .............................................. 60
Fitting to wooden wheels ........................................... 61
Fitting the pedestal bracket ....................................... 61
Slot 1 fitting ......................................................... 62
Slot 2 fitting ......................................................... 63
Bulkhead bracket fitting ............................................ 64
Cabling ...................................................................... 65
6.6 Tiller actuator installation ......................................... 67
Basic installation ....................................................... 68
Tiller pin installation (Part No. D001)................. 68
Mounting socket installation (Part No. D002) ..... 69
Installation accessories .............................................. 69
Pushrod extensions .............................................. 69
Tiller brackets ...................................................... 70
Cantilever mounting .................................................. 72
Pedestal socket mounting .......................................... 74
Installation ........................................................... 74
Tiller pins ............................................................. 75
Cabling and socket installation .................................. 75
Cabling................................................................. 75
Socket installation ................................................ 76
6.7 NMEA interface ........................................................ 77
Cabling ...................................................................... 77
NMEA data transmission to other equipment ........... 78
Data Formats ........................................................ 78
Transmission of NMEA data on SeaTalk ............ 79

xST4000PlusWheel&TillerAutopilotsOwner’sHandbook
Cha p t e r 7: Po st I nst a l l a t i o n Pr o ce d ur e s . . .. .. .. .. . .. .. .. .. . .. .. .. . 81
7.1 Functional test ........................................................... 81
Switch on ................................................................... 81
Operating sense ......................................................... 82
Navigation interface (GPS, Decca, Loran) ................ 83
Wind transducer interface ......................................... 83
SeaTalk interface ....................................................... 84
7.2 Dockside procedures ................................................. 85
Dockside rudder calibration procedure ..................... 85
Rudder offset adjustment........................................... 87
7.3 Initial sea trial ........................................................... 87
EMC conformance .................................................... 87
Overview ................................................................... 88
Automatic compass deviation correction .................. 88
Further heading alignment adjustment ...................... 92
Checking autopilot operation .................................... 92
Checking the rudder gain .......................................... 93
Chapter 8: Maintenance ...................................................... 95
General ............................................................................ 95
Servicing and safety ........................................................ 95
Advice ............................................................................. 95
Chapter 9: Fault Finding ...................................................... 97
Index ...................................................................................... 99

Chapt er 1: I nt r o duct i o n 1
Cha p t e r 1: I nt r od uct i on
1.1 Overview
The ST4000 Plus is a SeaTalkÆ compatible autopilot available for tiller
or wheel drive steering systems, which can also repeat instrument data
in a programmable selection of Data Pages.
The ST4000 Plus can share all data transmitted from other Raytheon
SeaTalk instruments:
ïWind information from a wind instrument can be used for wind trim
(Vane) steering without the need to install a separate vane.
ïTrack information, from a navigation instrument, provides waypoint
control from the autopilot.
ïBoat speed from the Speed instrument provides optimum track-
keeping performance.
The ST4000 Plus autopilot can also be used with any navigator (GPS,
Decca, Loran) transmitting NMEA 0183 data.
There are four operating modes:
Standby:Autopilot off
Auto:Autopilot engaged and locked onto a heading
Track:Autopilot maintains a track between two waypoints created
using a navigation system
Vane:Autopilot maintains a course relative to an apparent wind
angle
When the ST4000 Plus is being used to repeat instrument data, ìpop-up
pilotî pages are displayed for 5 seconds whenever a change in autopilot
control is made.
The ST4000 Plus also provides the following:
ïAutomatic tack facility, which can be used in Auto and Vane modes
ïAutomatic compass deviation correction
ïNortherly/Southerly heading compensation
ïAutomatic heading deadband ñ seastate control
ïWaypoint advance feature
ïSetup and calibration options to suit each installation, giving
maximum performance with many types of boat, with three
calibration menus (user, intermediate and dealer)

2ST4000PlusWheel&TillerAutopilotsOwner’sHandbook
ïDockside rudder calibration feature, which automatically
determines the characteristics of your installation, and adjusts for
them, before you set sail
ïRaytheon CodeLock security support
1.2 Extended syst ems
The ST4000 Plus is compatible with other Raytheon SeaTalk
instruments. Additional fixed and hand-held SeaTalk autopilot control
units can be connected at secondary steering and control positions.
A rudder reference unit can be fitted as an optional extra, and will
improve the wheel pilotís performance. It is especially recommended if
there is significant backlash in the steering system, or optimum
performance is required from a mechanical or cable steering system.
Note: You MUST fit a rudder reference if the ST4000 Plus is installed
on a hydraulic steering system.
1.3 Specification
ïPower Supply: 10 to 15†V dc
ïDrive mechanism: Wheel or Tiller, low current FET drive
ïCurrent consumption:
Standby: 60†mA (less than 200†mA with full lighting)
Auto: between 0.5†A and 1.5†A depending on drive type, boat trim,
helm load and sailing conditions
ïOperating temperature: 0∞C to +70∞C (32∞F to 158∞F)
ïEight button illuminated digital keypad
ïLCD display of heading, locked course and navigational data, with
three levels of illumination
ïInput connections for SeaTalk, power, fluxgate compass, rudder
reference unit and NMEA
ïOutput connections for SeaTalk and motor drive

Chapt er 2: Basi c Oper at i on 3
Cha p t e r 2: Ba si c Ope r a t i o n
This chapter first provides summary diagrams of the key functions and
screen layout. It then gives operating instructions for engaging the
autopilot and using Auto mode, changing the lighting, and displaying
Data Pages.
2.1 Key funct ions
The autopilot is controlled using simple push-button operations, all of
which are confirmed with a beep. In addition to the main single key
functions, there are several dual key functions.
TRACK
Press for Track
mode from Auto
AUTO
Press for Auto mode
DISP
Press for
Data Page
STANDBY
Press for Standby
mode
Course Change Keys
Port 1˚ Starboard 1˚
Port 10˚ Starboard 10˚
STANDBY plus AUTO
Press for Vane mode
-1 plus +1
Press for Response level
+1 plus +10
Press together
for AutoTack
to starboard
-1 plus -10
Press together
for AutoTack
to port
Press to accept
waypoint advance
Press for 1 second
to skip waypoint
Press for 1 second
for Last Heading
Press again to
accept Last Heading
Press for 1 second
for lamp control
Press and hold for
Setup modes
D3447-1
Press for 1 second
for Rudder Gain
Press for 1 second for Last Wind
Press again to accept Last Wind
ïThe autopilot always powers up in Standby mode. (If the text CODE
LOCK is displayed, enter your code as described in Chapter 4.)
ïCourse changes can be made at any time using the –1,+ 1,–10 and
+10 keys.
ïYou can return to manual steering at any time by pressing st andby
and disengaging the autopilot.

4ST4000PlusWheel&TillerAutopilotsOwner’sHandbook
2.2 Display layout
The following illustration shows all the elements, together with a brief
description, that make up the ST4000 Plus autopilot LCD display.
Rudder or Steer Direction Indicator
ïThe bar graph at the bottom of the display is normally a rudder bar.
If it has been set as a direction-to-steer indicator, the display depends
on the current mode, as follows:
Mode Bar
St a n d b y No t u sed
Aut o Heading error bar
Tr ack Cr oss t r ack er r o r ( XTE) bar , i n 0 . 02 nm i n cr ement s
Vane Wi nd angl e error bar
ïIf neither distance units (nm or SM ) is displayed, the distance is in
Km.

Chapt er 2: Basi c Oper at i on 5
2.3 Using Auto mode
Enga g i ng t he a ut op i l o t ( Au t o )
1. Steady the vessel on the required heading.
2. Engage the clutch lever (Wheel Pilot) or place the actuator over the
tiller pin (Tiller Pilot).
Extending and Retracting the
Tiller Pushrod
Use any of these
keys to extend or
retract the pushrod
Engaging the clutch
on the Wheel Pilot
1
2
D3395-1
3. Press auto.
D3560-1
ïIn Auto mode, the display shows the locked autopilot heading.

6ST4000PlusWheel&TillerAutopilotsOwner’sHandbook
CAUTI ON:
Passage making under autopilot control is an enjoyable experience
that can, if you are not careful, lead to the relaxation of the
permanent watch. A permanent watch MUST be maintained no
matter how clear the sea may appear to be.
Remember, a large ship can travel two miles in five minutes ñ just
the time it takes to make a cup of coffee.
Disengaging the autopilot (St andby) to return to
hand st eering
1. Press st a ndby.
D3561-1
ïIn Standby mode, the display shows the vesselís current
compass heading.
2. Disengage the clutch lever (Wheel Pilot) or remove the actuator
from the tiller (Tiller Pilot) to return to hand steering.
•Thepreviousautopilotheadingismemorisedandcanbe
recalled (see Returning to previous locked heading ).
Cha ngi ng cour se i n Aut o mo de
ïThe +1 and +10 (starboard) and –1 and –10 (port) keys are used to
change the locked heading, in increments of 1∞ and 10∞, when the
autopilot has control.
Example: a 30∞ course change to port = press –10 three times.

Chapt er 2: Basi c Oper at i on 7
Dodging obstaclesin Auto mode
In order to avoid an obstacle when your vessel is under autopilot
control, select a course change in the appropriate direction (for
example, port 30∞ = press –10 three times).
ïWhen safely clear of the obstacle, you can reverse the previous
course change (for example, press +10 three times), or return to the
previous locked heading (LAST HDG).
Re t ur ni ng t o t he pre vi ous l ocke d hea di ng
(LASTHDG)
If for any reason the vessel is steered away from the selected locked
heading (for example, executing a dodge manoeuvre or selecting
Standby) you can return to the previous locked heading:
1. Press auto for 1 second. The previous locked heading (LAST HDG)
is displayed for 7 seconds.