Simrad AP24 User manual

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Installation manual
Simrad AP24/AP28 Autopilots with
AC12/AC42 Autopilot Computers
English

Installation manual
Simrad AP24/AP28 Autopilots with
AC12/AC42 Autopilot Computers
English
Document no: 20222568
Revision: D
Date: January 2009
The original language for this document is English. In the
event of any discrepancy between translated versions
and the English version of this document, the English
document will be the official version.
To the best of our knowledge, the content in this
publication was correct at the time of printing.
As we are continuously improving our products we retain
the right to make changes to the product and the
documentation at any time. Updated manuals are
available from our website www.simrad-yachting.com,
and are free to download.
© Copyright 2009 by Navico Holding AS.

2 | AC12/AC42 Installation manual
About this manual
Rev. A 19.10.07 First issue
Rev. B 03.07.08 Corrections on system drawings.
Spare parts list updated.
Rev. C 10.11.08 Correction on board terminals
page 13.
Rev. D 27.01.09 Correction page 13.
This manual is intended as a reference guide for installing
and maintaining the Simrad AC12 and AC42 autopilot
computers and other components in an autopilot system.
Please take time to read this manual to get a thorough
understanding of the system components and their
relationship to a complete autopilot system.
Important text that requires special attention from the
reader is emphasized as follows:
Used to draw the reader’s attention to a comment or
some important information.
Used when it is necessary to warn personnel that a
risk of damage to the equipment or hazard exists if
care is not exercised.

AC12/AC42 Installation manual | 3
Content
1 System description ..................................... 5
1.1 General ..................................................5
1.2 How to use this manual.............................5
1.3 Software record.......................................6
2 Installation................................................. 7
2.1 Installation checklist.................................7
2.2 Unpacking and handling............................7
2.3 Determine system configuration.................8
2.4 Autopilot system layout.............................9
2.5 Autopilot computer installation.................11
2.6 Rudder Feedback installation ...................14
2.7 LF3000 Linear Feedback..........................16
2.8 Drive unit installation..............................18
2.9 AP24 and AP28 Control unit installation.....20
2.10 FC40 and RC42 Compass installation.......23
2.11 R3000X Remote Control installation ........24
2.12 JS10 Joystick.......................................24
2.13 S35 NFU Lever installation.....................25
2.14 Interfacing ..........................................25
2.15 SimNet ...............................................26
2.16 External Alarm.....................................30
3 Spare Parts List ........................................ 31

4 | AC12/AC42 Installation manual
4 Technical specifications............................ 35
4.1 AP24 Autopilot System............................35
4.2 AP24 Control Unit...................................36
4.3 AP28 Control Unit...................................38
4.4 Autopilot Computers............................... 39
4.5 FC40 Fluxgate Compass..........................41
4.6 RC42 Rate Compass ...............................42
4.7 RF300 Rudder Feedback..........................43
4.8 RF25 Rudder Feedback ...........................45
4.9 R3000X Remote Control..........................45
4.10 JS10 Joystick.......................................46
4.11 SimNet ...............................................47
4.12 IP protection........................................47
4.13 AT10 SimNet/NMEA0183 converter.........48
5 Index........................................................ 51

System description | 5
1System description
1.1 General
The autopilot computer is the main unit in the AP24 and
AP28 autopilot systems. It contains the steering
computer and electronics for the drive unit motor and
clutch and provides interface to other system
components. Two models, AC12 (8/16 A motor current)
and AC42 (30/50 A motor current) are available.
It communicates on the proprietary SimNet data and
control network to establish a reliable digital
communication and power distribution between the units
in the autopilot system as well as other Simrad products.
SimNet provides high speed data transfer and control of
Simrad products integrated in a total steering and
navigation system.
1.2 How to use this manual
This manual is intended as a reference guide for installing
and maintaining the Simrad AC12 and AC42 autopilot
computers and other components in an autopilot system.
Please take time to read this manual to get a thorough
understanding of the system components and their
relationship to a complete autopilot system.
Other documentation material that is provided with your
system includes an operator manual which includes the
setup instructions for the system, a control unit
installation guide and a warranty card. The warranty card
must be filled out by the authorized dealer that
performed the installation.

6 | System description
1.3 Software record
Control units
When the system is switched on, a status display shows
the serial number and software version for the control
unit.
The shown readout is only an example!
Autopilot computers
Serial number and software version for autopilot
computers and other SimNet sources can be found under
the control unit User setup menu. Refer to Manual source
selection in the autopilot operator manual.
1.4 Exchange of software program
For upgrading the software of Simrad products/devices,
refer to Manual for Software Upgrade Tool, part no.
20222956.

Installation | 7
2Installation
An autopilot system includes several units that need to
be mounted in different locations on the boat, and also
need to interface with at least three different systems on
the boat:
•The boat's steering system
•The boats electrical system (input power)
•Other equipment on board (SimNet interfacing)
In addition, the advanced capabilities of the system
require the installer to perform a series of settings and
tests to verify proper operation of the system, refer to
the check list below.
2.1 Installation checklist
1. Determine the system configuration you are
installing (Page 8)
2. Perform the hardware installation (Page 11)
3. Connect SimNet devices to SimNet (page 26)
4. Perform Set-up (refer to Operator manual)
5. Test Autopilot Operation at Sea (refer to Sea Trial
instructions in the Operator manual)
2.2 Unpacking and handling
Care should be taken when unpacking and handling the
equipment. A visual inspection should be made to see
that the equipment has not been damaged during
shipment and that all components and parts are present
according to the packing list.
An autopilot system will include:
•Control unit (AP24 or AP28) with accessories
−Installation accessories
−Operator manual

8 | Installation
•Autopilot computer (AC12 or AC42) with accessories
−SimNet cable 5,5 m (18’)
−Installation accessories
−AC12/AC42 Installation Manual
•Compass (FC40 or RC42) with 5,5 m (18') SimNet
cable attached
•Feedback unit (RF300 or RF25) with transmission rod
and cable attached.
•Appropriate drive unit for the installation (unless the
autopilot is going to operate an existing drive unit or
solenoids).
•Optional equipment that may have been ordered for
the installation.
2.3 Determine system configuration
It is important to become familiar with the configuration
of the system prior to beginning the installation. An
autopilot basic single station system is shown in Figure
2-1 and a system layout with options is shown in Figure
2-2
Plan your cabling and configure the SimNet network in
accordance with chapter 2.15 on page 26. Pay particular
attention to the autopilot computer/drive unit
combinations.
As most of the units are communicating on a common
network (SimNet) with identical connectors, the
installation is simple. Try to mount the units within the
standard cable length supplied with each unit. SimNet
cables are available from your distributor (see page 33)
for connection to other SimNet devices and cable
extension.
1On boats powered by outboards or stern drives it
may be difficult to install a rudder feedback unit
(Refer to RF300, RF25 or LF3000 in this manual).
Use of the Virtual Rudder Feedback, VRF™,
algorithms in the software may then be preferred
as this requires no installation of a rudder feedback

Installation | 9
unit. The VRF can be used on boats up to 40 ft.
2The VRF technology requires a Simrad rate
compass (RC42) for heading information to the
autopilot system.
2.4 Autopilot system layout
12/24V Motor supply
Drive unit
AP24
Control Unit
Multijoiner
Compass
5,5 m
5,5 m
5,5 m
24
AP
MODE
MENU AUTO STBY
TURN
1010
PWR
1
1
RF25 Rudder Feedback
12V SimNet supply
(SimNet cable with terminator)
Autopilot
Computer
Non SimNet
SimNet
Figure 2-1 AP24 basic system layout

10 | Installation
Drive unit
Non SimNet
SimNet
AP24
Control Unit AP28 Control Unit JS10
Joystick R3000
X
Remote
Control
RF300 Rudder Feedback Unit (optional)
LF3000 Linear Feedback (optional)
LFI3000
Interface
(optional)
RF25 Rudder Feedback Unit
12/24V Motor supply
24AP
MODE
MENU AUTO STBY
TURN
10
10
PWR
1
1
Autopilot Computer
Multijoiner
Compass
5,5 m 5,5 m
5,5 m
12V SimNet supply
(SimNet cable with terminator)
PWR
NAV W IN DTURN
STBY
DRIFT
NO- AUTO
MENU
Termination
plug
Figure 2-2 AP24 system layout with options

Installation | 11
2.5 Autopilot computer installation
The autopilot computer is designed to operate in a
location with ambient temperatures below +55°C
(+130°F).
The autopilot computer units (AC12 and AC42) should be
mounted vertically in a place between the control unit and
the drive unit.
The unit should not be exposed to dripping
or splashing water.
Figure 2-3 Autopilot computer mounting
Cabling
Use only shielded cables and ready made SimNet cables
and accessories. This includes motor supply, drive unit
cables and, if necessary, extension of the optional rudder
feedback cable(s). The clutch/bypass cable and the
solenoid cable should be 1,5 mm2(AWG14).
The motor supply cable and the drive unit motor cable
should have sufficient wire gauge. This will minimize
voltage drop and allow the drive unit to operate at full
power.

12 | Installation
Refer to the table below for recommended cable sizes.
Cable length Drive unit voltage
1. Breaker panel to autopilot computer. 12 V 24 V
2. Autopilot computer to drive unit motor
(Length refers to each of the two cables) AWG mm2AWG mm2
Up to 3 m (10 ft.) 12 2,5 12 2,5
Up to 6 m (20 ft.) 10 4 10 2,5
Up to 10 m (32 ft.) 8 6 10 4
Up to 16 m (52 ft.) 6 10 8 6
Remove the bottom cover to get access to the plug-in
terminals.
Provide sufficient wire length so that the plug-in
terminals can be easily connected and disconnected.
Pull out each terminal before connecting the wires.
Remove all strands before putting back the terminal
cover.
Plug-in terminal
Cable strap
Cable retainer
Ground terminal
Fuse

Installation | 13
A SimNet cable is supplied with the autopilot computer. It
has a connector only at the control unit end. The other
end is prepared for screw terminals.
AC12 Board Terminals
AC42 Board Terminals
Polarity protection
The fuse located in the lower left corner of the AC board
is not put in its final position when supplied from factory.
When the motor supply is connected to the terminal, a
diode will light. If the light is red, you have to swap the
wires. When the light is green, the polarity is correct.
Switch off the supply voltage and put the fuse into
correct position.
Radio Frequency Interference (RFI)
The autopilot system has excellent RFI protection as per
EMC Directive 2004/108/EC.
SimNet cables and other signal cables (feedback, NMEA)
should not be run in parallel with other cables carrying RF
or high current, such as VHF and SSB transmitters,
battery chargers/ generators, winches and thrusters.
If problems occur with RFI, make provisions to connect
the supply cable shield to the fast-on ground terminal.
This terminal must also be connected to the hull bonding.

14 | Installation
SIMNET
NET-S
NET-C
NET-H
NET-L
SPARE
Autopilot Computer
AP24 Control Unit
SimNet
RED
BLACK
YELLOW
BLUE
J1
J2
Figure 2-4 Control unit connection
J1 and J2 are the SimNet connectors.
2.6 Rudder feedback installation
The RF300 and RF25 Rudder feedback units mount close
to the rudder, and are mechanically linked to the rudder
tiller arm or rudder quadrant. Refer to Figure 2-5 for the
recommended mounting arrangement.
Do not remove the transmitter lever from the feedback
unit. The unit is factory adjusted and need no further
adjustment at installation than described below.
Turn the helm wheel to set the rudder tiller arm to
approximate centre position.
Set the mounting location to be in accordance with Figure
2-5. The centre of the feedback unit should be in line
with the centre of the rudder post. Mount the feedback
unit to a suitable platform using the screws provided. If
necessary, add blocking material under the feedback unit
to adjust the height of the transmitter lever to be level
with the rudder tiller arm.
Due to space limitations, it may be necessary to cut the
length of the transmitter rod to move the feedback unit
closer to the rudder post.
Rotate the feedback transmitter lever to centre position.
(Use the alignment mark to line up the transmitter lever
to be opposite the cable entry into the feedback).

Installation | 15
Carefully observe the alignment marks. A rudder
feedback alarm may be the result if the alignment
instructions as per Figure 2-5 are neglected.
Figure 2-5 Rudder feedback mounting (019356)
Note that the transmitter lever has two slots for the
transmitter link. The slots enable maximum flexibility to
provide the 1:1 mechanical linkage relationship. As a
starting point, set the transmitter rod to the inner limit of
the outer slot if possible. (Refer to Figure 2-5). Drill and
tap the rudder tiller arm so that the Y1 dimension is
equal to the Y2 dimension (Use 4.2 mm drill and 5 mm
tap). Attach the ball joint to the tiller arm, and connect
the transmitter rod to the ball joint at the rudder tiller
arm.
Tighten the mounting screws for both the feedback unit
and the transmitter rod ball joint.
Observe the feedback unit while someone turns the helm
wheel through the complete travel H.O. to H.O. and
verify that the mechanical linkage moves freely.

16 | Installation
Autopilot Computer
*
Non polarized
(color independent)
Optional RF300 Rudder Feedback
*
RUDDER
Figure 2-6 RF300 connection
RF25 Rudder Feedback Unit
8-16V SimNet supply SimNet
T-joiner
Figure 2-7 RF25 connection to SimNet
2.7 LF3000 Linear Feedback
The rod of the LF3000 is not locked in place in the
cylinder. Pay attention as it may slip out of its
housing and end up on the seabed.
The LF3000 is a waterproof feedback unit. It has a 300
mm (11,8") stroke and comes with a special mounting
bracket which secures the LF3000 to the cylinder of the
existing outboard drive unit.
The 8,5 m (28') cable is terminated in the LFI3000 Mk2
Linear Feedback Interface according to Figure 2-9.
The mounting hardware provided is made to interface with
Teleflex HC5340 cylinders and Hynautic K7 and K10

Installation | 17
Cylinders. The hardware may not be appropriate for other
systems.
Center the drives. Loosely secure the LF3000 to the
supplied mounting bracket, across the center of the drive
unit cylinder. Either cylinder may be used if there is a dual
set up. You may mount the feedback in either direction,
i.e. the shaft of LF3000 may point to port or starboard.
Loosen the end bolt (a) used to secure the cylinder to the
drive unit mount. Insert the rod retaining assembly (b)
and retighten the bolt. Secure the feedback rod to the
retainer plate using the two washers and the cap nut
provided. Adjust the location of the LF3000 Linear
Feedback to allow full travel of the hydraulic cylinder
without causing the retainer plate to hit the end of the
cylinder. Check that the outboard motor can be tilted
freely. Tighten all nuts and the mounting bracket.
Turn the helm slowly by hand to the stop on either side,
check that the rod does not bind up in any direction. Make
a “drip nose” (c) on the cable to the unit and clamp the
cable to allow full engine movement to port and starboard.
LF3000
BRACKET
CYLINDER
(END VIEW)
RETAINER PLATE
LOCK NUT FLAT WASHERS (2) LF3000
LINEAR FEEDBACK
ALLEN HEX SCREWS (2)
FLAT WASHERS (2)
MOUNTING BRACKET
CLAMPS (2 HALVES)
Figure 2-8 LF3000 mounting
a
b
c

18 | Installation
Autopilot Computer
RUDDER
*Non polarized
(color independent)
LFI3000 Mk2
Interface LF3000
Linear
Feedback
*
TB2TB1
WHITE
BROWN
YELLOW
GREEN
BROWN
WHITE
Figure 2-9 LF3000/LFI3000 Mk2 connections
2.8 Drive unit installation
The relations between drive units, drive unit voltage,
autopilot computer, drive performance and interface to
the steering gear are shown in the tables below.
Refer to the connecting diagram for the different drive
units on page 19 onwards.
Installation instruction for the drive units are found in the
manual for the individual units.
The maximum drive current capability of the AC12 and
AC42 autopilot computers are different. Use the table
below as reference and observe the notes on next page.
HYDRAULIC PUMPS
RAM CAPACITY
MODEL MOTOR
VOLTS AUTO- PILOT
COMPU-
TER
MIN
cm3
(cu. in.)
MAX
cm3
(cu. in.)
FLOW RATE
AT 10 bar
cm3/min
(cu. in/min)
MAX
PRESSURE
bar
PWR.
CONSUM-
PTION
RPU80 12V AC12 80 (4,9) 250 (15,2)
800 (49) 50 2,5-6 A
RPU160 12V AC42 160 (9,8) 550 (33,5)
1600 (98) 60 3-10 A
RPU300 12V AC42 290 (17,7)
960 (58,5)
3000 (183) 60 5-25 A
RPU300 24V AC42 290 (17,7)
960 (58,5)
3000 (183) 60 2,5-12 A

Installation | 19
LINEAR DRIVE UNITS
MODEL MOTOR
VOLTS AUTO- PILOT
COM-
PUTER
MAX
STROKE
mm (in.)
PEAK
THRUST
kg (lb.)
MAX
RUDDER
TORQUE
Nm (lb.in.)
HARD-OVER
TIME
sec.
(30% load)
PWR.
CON-
SUMP.
TILLER
ARM
mm
(in.)
DD15 12V AC42 – – 150 Kgm 2 A –
HLD350 12V AC12 200 (7,9)
350
(770) 610 (5400) 12 2,5-8 A
175
(6,9)
HLD2000L 12V AC42 340 (13,4)
500
(1100) 1460 (12850)
19 3-10 A
298
(11,7)
HLD2000D 24V AC42 200 (7,9) 1050
(2310) 1800 (15900) 11 3-10 A
175
(6,9)
HLD2000LD
24V AC42 340 (13,4)
1050
(2310) 3180 (28000) 19 3-10 A
298
(11,7)
MSD50* 12V AC12 190 (7,5)
60
(132) – 15 0,8-2 A
–
Steering gear interface: Connects to quadrant or tiller.
* For stern drive power assisted steering only.
1. For 12V drive units the motor voltage is stepped
down by the autopilot computer when operating from
24V supply.
2. The specified autopilot computer is necessary to
achieve max drive unit capacity.
3. Recommended operational thrust or torque is 70% of
listed peak value.
4. Typical average power consumption is 40% of listed
maximum value.
Connecting a reversible pump
+
DRIVE
DRIVE
ENGAGE
SOL.-MOTOR
SOL.-MOTOR
SOL.GND
AC12 Autopilot Computer
SIMRAD Reversible Pump
Figure 2-10 Connecting a reversible pump