Simrad Navico WP10 User manual

WHEEL PILOT
WP10 & WP30
SERVICE MANUAL

Issue 1.1 19/09/03 SIMRAD
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Simrad Margate Ltd
Star Lane, Margate, Kent CT9 4NP,UK
Telephone [phone]
Facsimile [phone]
E-Mail : [email protected]
CONTENTS
1 INTRODUCTION
1.1 Electronic PCBs
1.2 Mechanical Components
2 OPERATION
3 DIS-ASSEMBLY / ASSEMBLY INSTRUCTIONS
4 MECHANICAL ASSEMBLY DRAWINGS
5 CIRCUIT DESCRIPTIONS
6 CIRCUIT DIAGRAMS
6.1 Circuit Schematics
6.2 Component Lists and Layouts
7 PROGRAMMING AND CONFIGURATION
8 FAULT FINDING
8.1 Common User Faults
8.2 Common Technical Faults
9 SPARE PARTS DETAIL
9.1 Spares
9.2 Service Aids
9.3 Accessories
10 TECHNICAL NOTES
© 2003 Simrad Margate Ltd
The technical data, information and illustrations contained in this publication were to the best of our knowledge correct at the time of going to print. We
reserve the right to change specifications, equipment, installation and maintenance instructions without notice as part of our policy of continuous
development and improvement. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic or
otherwise without prior permission from Simrad Margate Ltd. No liability can be accepted for any inaccuracies or omissions in the publication, although
every care has been taken to make it as complete and accurate as possible.

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Wheel Pilot WP10 & WP30
Section 1
Introduction

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1 INTRODUCTION TO THE WP10 AND WP30 WHEELPILOT
The WP10 and WP30 Wheelpilots offer the benefits of high performance, low power consumption
and quiet operation together with weatherproof protection and user friendly operation. They are
entirely self-contained, all components – drive, compass and control pad are housed in a single
unit with no separate compass to fit. Installation can be completed in minutes and with the
exception of running the power supply cable there are no holes to be drilled.
Two models are available to suit all wheel steered sailing boats up to 12M (40 ft) in length.
The WP10 is a high power, wheel autopilot which delivers up to 70Nm torque and is suitable for
vessels up to 10m (32 ft) in length
The WP30 – offers the same functions and design advantages as the WP10 but with more power,
a built-in NMEA0183 interface and Corus compatibility. The WP30 has a torque of 80Nm and is
suitable for vessels up to 12m (40 ft) in length. The built-in NMEA 0183 interface (4800 baud)
facilitates the connection of any NMEA compatible GPS directly to the pilot allowing the vessel to
be steered to GPS (NavLock Mode). NMEA compatible wind vanes can also be connected
allowing the vessel to be steered to wind. GPS and Wind data can also be supplied at 75 kBaud
from a Corus instrument system using the built-in Corus interface. Data from an external fluxgate
compass ATC600 provides more accurate course keeping and enables the pilot to be installed on
ferrous hulled vessels. This faster and more accurate interface also allows the CP600 Corus
Programmer to be used as a remote control and any C600AD Active Display on the Corus network
can be configured as a remote control unit. A low cost hand remote, HR200, is also available and
can be linked to the pilot via the NMEA interface.
The main components of the Wheelpilot are described below:
Electronics PCBs
Early versions
WP10 PCB (WP10)
WP30 PCB (WP30)
Current Versions. The same PCB is used for both products. The wiring
loom carrying the NMEA data is left disconnected in the WP10.
WP10 / 30 Re-engineered PCB (Common to both)
Mechanical Components
General Assy : WP10
General Assy : WP30

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Wheel Pilot WP10 & WP30
Section 2
Operation

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2 OPERATING SIMRAD
This Service Manual only contains operating instructions for those features of the Simrad Wheel
Pilot range that are not normally available to the end user. For details of normal operation please
refer to the appropriate Simrad Instruction Manual.

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Wheel Pilot WP10 & WP30
Section 3
Assembly Instructions

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3 ASSEMBLY INSTRUCTIONS
General Assembly. Refer to Drawing No. E03515 (E03516 for WP30). With the exception of the
extra cable loom in the WP30, assembly is identical.
Note: Lubricant is not required; all components should be assembled dry.
Clutch Plate Assembly. Refer to Drawing No. E03047 and assemble the clutch plate as shown
ensuring that the M4 Half Nut 200251 locates into the hexagon nut retainer in the end of the Clutch
Roller Shaft and is locked by the application of a small quantity of Green Loctite 270 – 206625 onto
the screw thread prior to assembly. Ensure roller assemblies both revolve freely.
Rear Plate Assembly. Refer to Drawing No. E03018 and fit an M8 Washer 20023 onto each of the
two M8 x 30 Bolts 200243 ensuring that the rounded or smooth side of the washer faces the head
of the bolt and screw the bolts into the Rear Plate E02973 as shown. When the head of the bolt is
within 6mm of the plate apply a small quantity of Green Loctite 270 - 206625 onto the thread of the
screw, under the head, and fully tighten with an M13 spanner. Assemble the 6 Ring Roller
Assemblies and fit to the Rear Plate securing each Button Headed Screw 200231 with a Nyloc Nut
200259 sufficiently to retain the assemblies but without fully tightening
Clutch Handle Assembly. Refer to Drawing No. E03045 and into the boss of the Clutch Handle
E02989 fit Adjusting Screw E03039, ensuring that the slot in the head of the screw can be seen
through the slot in the side of the boss.
Fit the Tension Adjuster E02988.
Drive Ring Assembly. Refer to Drawing No. E03046 and fit the 2 Spoke Splines E02968:BK to
the outside of the Front Guide Ring E02967 ensuring that the peg on the spoke spline locates into
the outer hole, in the drive ring. Add a small quantity of Loctite 270 Green 260025 to the end of the
thread of the screw protruding through into the front drive ring and fully tighten the M4 Half Nut
200147.

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Pulley Magnets Sub-Assembly. Refer to Drawing No E03050 and the sketch below and fit the
magnets noting that it is important to maintain the correct polarity.
Wiring to PCB Assembly. Refer to the sketch below, cut the wires to length, prepare them by
stripping, twisting and tinning the ends and solder them to the PCB as shown.
PCB Case Assembly. Refer to Drawing No. E03053 (E03054 for WP30). Into the case bottom fit
a compass and support assembly and secure using 2 off No. 4 X 1/4 screws 200104 and fully
tighten. Connect the compass to the PCB. Fit the Case Seal E02979 into the groove around the
case top and bring the case down onto the top ensuring the seal is still located correctly. Screw
the top to the case using 6off No.4 X1/2" Screws 200002, and fully tighten.
Gearbox and PCB Case Assembly. Refer to Drawing No. E03086 and fit the Ball Race Seal
E03243 onto the Gearbox Assembly E03050. Offer up the gearbox assembly to the Rear Plate
E03018 and fit 2 Screws M5 x 8 Csk Pan Poz 200242 through the rear plate into the gearbox
assembly, opposite each other, but do not fully tighten at this stage. Fit the 2 Screws M5 x 35 Csk
Pan Poz 200241 through 2 of the pillars of the gearbox, add a small amount of Pink 222 Loctite
2600261 to the threads, fit an M5 half nut onto each and fully tighten all 4 screws.

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Refer to Drawing No.E03018 and fit a Rubber Grommet 190013 to the Rear Backing Ring E03018.
Peel off the backing paper from the self adhesive side of the Connector Seal E02985 and stick this
to the Rear plate where shown. Apply Hellerman Sleeving Oil to the Motor Cable of the PCB Case
Assembly and guide the cable through the grommet as the PCB Case Assembly is offered up to
the rear plate and pull the cable through so that the case sits onto the seal. Secure it to the rear
plate with 4 Screws M4 x8 Pan Poz 200210.
Refer to Drawing No. E03051 and press the cable into the channel on the drive ring. Refer to
drawing No. E03057 and push the cable down through the drive ring and the grommet in the gear
box. Pull tight and fit a Tie Wrap 200025 around the cable on the gearbox side to provide strain
relief. Route the wire around the side of the gearbox and out again through the lower grommet.
Apply a bead of Silicone and seal in the motor cable to the grommet from the PCB Case. Fit a Mu
Metal Shield E02992 around the outside of the motor and solder the 2 wires on to the motor
ensuring that the Red wire is soldered to the tag with the Red mark and that the wire is laid around
the motor as shown below to provide strain relief.
When the motor solder joints are made, fit a tie wrap around the Mu metal shield and the Black and
Red wires to retain shield and wires.
Hall Effect PCB Wiring and Gearbox Cover Fitting. Refer to Drawing No. E03057 and solder
the Blue, Yellow, Green and White wires onto the Hall Effect PCB E03184. Fit the PCB into the
Front Gearbox Cover E03043 and screw in using 2 No. 4 x 1/4" 200104. Fit front printed cover
onto gearbox and retain with one No. 4 x 5/8 Screw 200067, do not fully tighten. Fit Clutch Handle
Assembly E03045 into position on gearbox drive ring and the Rear Gearbox Cover E02980 and
retain with 2 off No. 4 x3/4 Csk Screws 200254 on the inside of the ring. Fit the 4 No. 4 x 5/8 Pan
Head Screws 200067 through the gearbox and into the top cover and fully tighten all screws.
Clutch Plate Assembly. Locate the PTFE Clutch Shim E03040 and, ensuring that it is orientated
correctly onto the cross pin, pass it over the gearbox output shaft so that it lays flat against the
drive ring. Place Clutch Plate Assembly E03047 onto the clutch shim secure a Clutch Shoe
E03041 to the plate assembly through the clutch shim and gearbox ring and secure with an M4 X
16 Csk Screw 200295, M4 Nyloc Nut 200259 and a small quantity of Green Loctite 270 – 260025.
Do not fully tighten at this stage. Fit the second clutch shoe to the other end of the clutch plate and
secure into the Clutch Handle Assembly previously fitted into gearbox cover and ring. Fit the
Pulley Flange E03036 onto the gearbox output shaft and secure through the shaft with an M3 x 16
Dowel Pin 200234 and then the 16T Pulley E03044 retained by 2 No.4 x 3/8 " Screws 200079.
Tighten the Clutch Shoe screws until operating the clutch handle presents resistance but still
allows the clutch plate to operate smoothly. Fully tighten the remaining screws.

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Final Assembly. Refer to the sketch below and set the clutch handle to the midway position.
Position the clutch roller plate so that the two rollers on the plate are equidistant about the 16T
drive pulley. Fit the belt as shown, and push the clutch lever up to capture the belt. Check all the
rollers are loose.
WARNING Care should be exercised in the following operation to avoid trapping fingers.
Place the Drive Ring Assembly (Spinning) over the belt in between the gear box housing, push the
belt up into ring and tuck the six rollers into the drive ring. When all the rollers are in the ring, turn
the unit over and tighten the six mushroom head screws on the rear.

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Wheel Pilot WP10 & WP30
Section 4
Mechanical Assembly Drawings

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4 MECHANICAL ASSEMBLY DRAWINGS
General Assembly : WP10 E03515
Clutch Plate Assembly E03047
Rear Plate Assembly E03018
Clutch Handle Assembly E03045
Drive Ring Assembly E03046
Gearbox Assembly E03050
PCB Case Assembly E03053
Gearbox and Ring Assembly E03086
Gearbox Ring / PCB Pod Assembly E03057
General Assembly : WP30 E03516
PCB Case Assembly E03054

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