Volvo Penta VolvoPenta IPS Autopilot System DPU Guide

VolvoPentaIPS
Autopilot
System
DPU Installation
and System
Connections
DocumentNumber: 870543
Date:July 2006
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2 Volvo Penta IPS Autopilot System
Handbook information
Tothe bestof ourknowledge, theinformationinthis handbook wascorrectwhen
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.
Autohelm,HSB (High Speed Bus), SailPilot, SeaTalk and SportPilot are registered
trademarks of Raymarine Ltd.
Raymarine, SmartPilot,AST (AdvancedSteering Technology), AutoAdapt,
AutoLearn, AutoRelease, AutoSeastate, AutoTack, AutoTrim, FastTrim, GyroPlus,
RayGyro, RayPilot and WindTrim are trademarks of Raymarine Ltd.
Handbook contents © Raymarine Ltd 2005 2006.
Installation Procedures
1.1 Introduction
The Volvo Penta IPS Autopilot System consists of an IPS S3G Course Computer
core pack and an IPS DPU.
TheIPSS3GcorepackcontainsaCourseComputerandafluxgatecompass.There
is no need tofit a drive unit or rudder feedback unit. This system can onlybe used
with a Volvo Penta IPS system.
TheIPSAutopilotsystemiscompatiblewithST6001,ST7001andST8001rangeof
autopilot control units. Raymarine wireless controllers, the S100 or
SmartController can be fitted as optional extras.
This handbook will guide you through the installation of your IPS DPU and the
connections that you will needto make to the other parts of the IPS system.
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Please refer to the back of this handbook for a detailed schematic diagram
1.2 Parts Supplied
s
Additional parts required
Tocomplete the installation you will also require the Autopilot Interface kit from
Volvo Penta. Part Number 3819744, comprising of a Gateway, Ysplit, Assembly
instruction and tiewraps.
D8065-1
Data Processing Unit
(DPU)
Volvo Penta IPS System - Top Level Schematic
Fluxgate
Compass
ST6/7/8001
Control Head
IPS S3G
Course Computer
to Volvo Penta
autopilot interface
Grounding cable, 2 meters
Plug to unterminated
(supplied with the S3G) D8035-2
Terminator
Plug
SeaTalk2Cable, 1.0 meter
Plug to unterminated
SeaTalk2Cable, 0.4 meter
Plug to unterminated (x2)
NMEA 0183 Cable,
0.4 meter unterminated
Data Processing Unit
(DPU)
Tie Wraps
SeaTalk Cable, 1 meter
to unterminated
5-way Junction Block
Data Processing Unit - Parts Supplied.
Junction Box
Ferrite
(x5)
Raymarine VP interface cable
(Connector to unterminated.
Supplied with the S3G)
CAUTION
DO NOT CONNECT TO NMEA2000 BUS
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4 Volvo Penta IPS Autopilot System
1.3 Planning the installation
Important Safety Information
WARNING: Product installation
This equipment must be installed and operated in accordance
with the Raymarine instructions provided. Failure to do so could
result in poor product performance, personal injury and/or
damage to your boat.
Because correct performance of the boat’s steering is critical for safety, we
STRONGLY RECOMMEND that an Authorized Raymarine Service Representative
fits this product.
WARNING:
The DPU and S3G Course computerare not suitable for use inthe
vicinity of engines, fuel tanks or inany other areas where fuel
vapor is likely to be present.
WARNING:
Make sure you haveswitched off thepower supply before you
start installing this product.
WARNING: Navigation aid
Although we have designed this productto 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
MULTILINK MULTILINK
D8036-1
Y-split cable - 3588206
Autopilot Gateway - 3819743
Tie Wraps
Autopilot Interface Kit - Volvo Penta part number 3819744
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5
replace commonsense and navigational judgement.Always
maintain a permanent watch so you can respond to situations as
they develop.
EMC Installation Guidelines
Please refer to the SmartPilot Commissioning Guide for applicable EMC
guidelines
Product disposal
When you want todispose of this product (for example, at the endof its
workinglife), please do so in accordance with local regulations.
1.4S3G Course Computer
Please refer to the SmartPilot Commissioning Guide for detailed installation
instructions for the IPS S3G and fluxgate compass.
1.5 Control Head
Please refer to the Control Head installation sheet for detailed installation
instructions.
1.6 Data Processing Unit(DPU)
D5536-1
5.9 in (150 mm) 1.53 in
(39 mm)
5.12 in (130 mm)
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6 Volvo Penta IPS Autopilot System
CAUTION: The DPU is not waterproof and so must be installed in a
dry location.
The DPU must be positioned below decks in a dry location where:
• It is protected against physicaldamage.
• It is at least 9 in (230 mm) from a compass.
• It is at least 20 in (500mm) from radio receiving equipment.
• There is reasonable access for installationand servicing.
Fitting the Data Processing Unit
Fit the Data Processing Unit toa vertical surface, as follows:
1. Remove the outer cover.
2. Place the DPU in the required position andmark the position of the fixing
holes.
3. Using a1/8 in(3.5 mm) drill,drilla pilothole foreachof the two fixingscrews.
4. Screw one of the selftapping screws provided(No8 x 1 in) into eachhole, so
each screwheadis at least 15 mm from the surface.
D5794-1
1
2
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7
5. Place the fixingholes over the screw heads, then move the DPU down so the
screw heads are at the top of the keyhole slots.
6. Tighten the selftapping screws to secure the DPU in position.
1.7 Running SeaTalk & NMEA2000 cables
Cable routing practices
When running cable,always observe the following guidelines:
• If a cable has tobe fed through the deck, always use a good qualitydeck
gland.
• Wherecables arefedthroughholes, always usegrommetstopreventchafing.
• Secure long cable runs so theydo not present a hazard.
• Wherever possible,route cables away from fluorescent lights, engines and
radio transmitting equipment,as these may cause interference.
Identifying cables
SeaTalk,SeaTalk
2
and NMEA2000busesareusedinthissystem.SeaTalkusesa 3
corecable.SeaTalk
2
andNMEA2000usea5core,screenedcable.Eachcabletype
isavailableinbothmadeupformwithprefittedconnectors,andinunterminated
form on a drum.
D5776-1
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8 Volvo Penta IPS Autopilot System
Bus connectors
If you are working withunterminatedcable, use the details in the table below to
ascertain the correct connections. Cable boots are available tocover the spade
terminals used to connect unterminated SeaTalk
2
cables.
SeaTalk and NMEA2000 connections
1.8 System power
CAUTION:
Incorrectly connected powersupplies could cause damage to the
system
THE DPU IS POWERED VIA THE SEATALK CONNECTION. DO NOT CONNECT ANY
OTHER POWER SOURCE TO THE DPU.
SeaTalk SeaTalk
2
and NMEA 2000
Wire Function Wire Function
Red 12 V + Shield Screen
Uninsulated 12 V  Red 12V +
Yellow Data Black 12V 
White Signal line high
Blue Signal line low
D5786-2
SeaTalk connector connector
SeaTalk 2
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9
Single power supply into SmartPilot computer
Separate SmartPilot computer and instrument power
Another option isto provide separate power supplies to the SmartPilot computer
and SeaTalk systemso you can have independent, switched instrument andpilot.
D9247-1
DPU
Computer
power supply
(via breaker/fuse)
SmartPilot
computer
Single power supply
SmartPilot
controller SeaTalk instruments
SeaTalk
SeaTalk
SeaTalk
SeaTalk bus
D9246-1
DPU
Computer
power supply
(via breaker/fuse)
SmartPilot
computer
Separate SmartPilot computer and instrument power supplies
SmartPilot
controller SeaTalk instruments
SeaTalk bus
SeaTalk
SeaTalk
SeaTalk
SeaTalk
Instrument SeaTalk
bus 12 V power supply
(via breaker/fuse
rated at 5 A or less)
Screen Do not connect Red wire
(Cut back and insulate)
Yellow
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10 Volvo Penta IPS Autopilot System
1.9 Cable preparation
In an IPS system,cables not already fitted with molded connectors must be
correctlyprepared for connection.
The DPU uses colorcoded, spring retentionconnectors. To make a secure
connectiontoaspringretentionconnector,preparethe cableforconnection,then
use the method illustrated below to connect each wire.
1.10 Connections to DPU
The diagram below illustrates the connections that are required to and from the
DPU.
Ferrites
Ensure that all cables connected to the DPU have a clipon ferrite fitted.
50 mm 9 mm
D5905-1
9 mm
D5907-1
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11
SeaTalk
Using the appropriate cable,connect the SeaTalk terminal on the DPU to one of
the SeaTalk terminals on the S3G Autopilot. You will need to cut off the molded
plugand strip the cable as described above.
Note: Note thatthe terminals are color coded tomatch the cable.
SeaTalk
2
Connecttheredandblackwiresofthe SHORTSeaTalk
2
cablestotheredandblack
terminals on the DPU. Ensure the remaining wires are suitably cut back and
insulated. Plug the other end into the SECOND terminal of a 5way SeaTalk
2
connector block.
NMEA 0183
ConnecttheNMEA 0183terminalon the DPUtothe NMEA1 terminal onthe S3G
course computer. Ensure that the following connectivity is achieved:
SeaTalk2Connector Block
SeaTalk
NMEA 0183
D8037-2
NMEA 2000
Yellow
grounding cable
RF ground
12345
DPU
toVolvo Penta
Autopilot
Interface Unit
S3G Course
ComputerTerminals
SeaTalk2
CAUTION
DO NOT CONNECT TO NMEA2000 BUS
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12 Volvo Penta IPS Autopilot System
NMEA 2000
Usingoneof theSHORTSeaTalk
2
cables,connect the NMEA2000terminalonthe
DPU to the FOURTH terminal of the 5way SeaTalk
2
connector block.
Securing cables and replacing cover
When all of the DPU cables have all been connected, secure each cable to the
loops on the DPU, using the cable ties provided.
When all cables are secure, replace the DPU cover.
Do not use the DPU withthe cover removed, as this could degrade the EMC
performance.
1.11 Additional connections
Three more connections now need tobe made to the 5way connector block.
SeaTalk
2
terminator
Plug the SeaTalk
2
terminator into the CENTER terminal onthe 5way SeaTalk
2
connector block.
Grounding the system
In order tomeet the system EMCspecification, the SeaTalk
2
cable screen must be
connected to the vessel’s RF ground point.
Using the grounding cable
Raymarine provide amadeup,RF groundingcable that youare recommended to
use, toground the system.
The grounding cable is yellow andhas a SeaTalk
2
connector at one end. Connect
this to the FIRST terminal of the 5way SeaTalk
2
connector block. The
Wire Color DPU Connection S3G Connection
Red NMEA 0183 In + NMEA 1Out +
Blue NMEA 0183 In  NMEA 1Out 
Yellow NMEA 0183 Out + NMEA 1In+
Green NMEA 0183 Out NMEA 1In 
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13
unterminatedendofthecableisstripped,forconnectiontothevessel’sRF ground
point.
If you require additional advice on grounding the IPS DPU,please contact the
Raymarine Technical Support Department.
1.12 Connecting to the Volvo Penta system
Volvo Penta Gateway
CAUTION:
Consult your Volvo Penta dealer before making any changes to
your existing system.
Note: ToconnecttotheVolvoPentasystemyouwillneedtoobtainanAutopilotInterface
kitfrom Volvo Penta.PartNumber3819744, comprising of a Gateway, Ysplit, Assembly
instruction andtwo tiewraps.
Plugthe LONG SeaTalk
2
cable into the FIFTHterminal of the 5way SeaTalk
2
connector block.
Threadthe cable into the junction box and connect to the connector block.
Then, threadthe bare endof the Raymarine VP interface cable into the junction
box and connect to the connector block. Ensure that the wire colors match.
CAUTION:
Do NOT connect the Raymarine VPinterface cableto NMEA2000,
or the systemcould malfunction.
Connect the otherendof theRaymarineVP interface cable(circular connector) to
the connector on the Volvo Penta Gateway.
D7940-2
1
2
CAUTION
DO NOT CONNECT TO NMEA2000 BUS
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14 Volvo Penta IPS Autopilot System
Ysplit cable
Connect the Ysplit cable to the Volvo Penta Gateway. Use the connection that
DOES NOT have a yellow “MUTILINK” label.
Finally,connecttotheVolvoPentasystembususingthe “MULTILINK”endsofthe
Ysplit cable.
1.13 EMC Conformance
Always check the installation before going to sea to make sure that it is not
affectedby radio transmissions, engine starting etc.
1.14 Postinstallation Checks
Before you proceed to the commissioningstage, it is important to verify your
installation. Please follow these simple procedures before commissioning:
D7941-1
MULTILINK MULTILINK
3
D7942-2
MULTILINK MULTILINK
MULTILINK MULTILINK
4
5
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15
1. Power up the IPS autopilot system and start the Volvo Penta IPS engines
Move the helm byhandand observe the ships rudder gauge and the rudder
bar on the control unit. These displays shouldbe synchronized.
If they are not:
i. Check thatthe Volvo Penta autopilotinterface isconnectedcorrectly. You
will need to consult your Volvo Penta service agent.
ii. Check that the connections in the junction box match color for color, at
the connector block.
iii. Check the NMEA OUT connections at the DPU and that they are seated
properly in the connector.
iv. Check the NMEA IN connections at the S3G and that theyare seated
properly in the connector.
2. Drive the boat at a slow speed (approximately 5 knots) and press AUTO on
the control unit. Your boat should continue on its current heading.
If the control unit reads “NO IPS” then repeat the wiring checks in step 1.
3. Use either the +10 or 10keys or the rotary control to make a course change.
Your boat should alter course as directed.
If the autopilot does not respond, then repeat the wiring checks in step 1.
4. The autopilot is now readyfor the commissioning process. Please refer to the
commissioning section of the SmartPilot Commissioning Guide.
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16 Volvo Penta IPS Autopilot System
Computer power supply (via breaker/fuse)
SeaTalk2Connector Block Volvo Penta IPS Autopilot
System Connections
(Single power supply)
Yellow grounding cable
ST6001
Control Head
RS125
GPS
RF ground
Compass
Junction Box
IPS Data Processing Unit
D8055-3
S3G Course Computer
12345
toVolvo Penta
Autopilot
Interface Unit
CAUTION
DO NOT CONNECT
TO NMEA2000 BUS
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