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. AUTOHELM 4 0 0 0 Autohelm 4000 is an up-to-the-minute digital autopilot which shares the same microprocessor technology built into our biggest and most sophisticated fully installed pilots. It will provide precise powerful steering for sailing yachts up to 13m (42ft) LOA. The basic system comprises the main control unit, wheel drive unit and mountinq fittinqs (Fiq. 2). This can be nde8by ad&ng any of the following The full system is shown below (Fig. 1) The system is designed for owner installation which aided by the following guide should prove to be a simple and interesting job. After fitting the equipment it is only necessary to make a single adjustment to the control unit to match the autopilots response to the steering characteristics of your vessel. Good Sailing! l Windvane 0 Radio navigation interface 0 Hand held control unit Fig.1 MAIN CONTROL UNIT HAND HELD CONTROL UNIT (OPTION) WINDVANE RADIO NAVIGATION INTERFACE (OPTION) INSTALLATION WHEEL DRIVE UNIT The wheel drive unit (Fig.2) is attached to the vessel's wheel using the clamps supplied. To complete the installation it is only necessary to screw the torque restraint bracket to the pedestal. It has been designed for permanent mounting in the cockpit and requires no maintenance whatsoever. A single lever disengages drive for manual steering. STEERING SYSTEM The Autohelm 4000 is designed to operate with steering systems having between 1 and 3.5 turns lock to lock. Steerinq systems with more than 3.5 turns may ca&e impaired steering performance due to reduced rate of rudder application. Lost motion in the steering system must not exceed 1% of total movement. This is equivalent to 7.5 degrees of free wheel movement for a system with two turns lock to lock. If lost motion exceeds this level it must be corrected otherwise steering performance will be impaired. It is recommended that the wheel driv L\ is not used on hydraulic steering systemi ' *-d Hydraulic slip across the helm pump produces significant lost motion which will impair steering performance. ATTACHMENT TO THE WHEEL The drive unit is clamped to the wheel spokes using the bolts and clamps provided, and may be used on wheels with 3,5 or 6 spokes (Fig. 3). Fig.3 AI8 The drive unit must be mounted between the wheel and the pedestal (Fig. 2). The attachment kit has three romplete sets of clamps to compensate for differing spoke diameters. Marked alongside each clamp is the spoke diameter to which it relates. The appropriate clamps are simply broken off as required. The spacers (Fig. 5) must be used when the wheel is dished (Fig. 6) t9 prevent distortion of the drive unit when the fixing bolts are tightened. Fig.5 Fig.2 SPACER WliEEICI.AMPS I A holes - 3 and 6 spoke wheels B holes - 5 spoke wheels For 4 spoke wheels, use a 4.0mm (5/32irr) drill to open out iht> C pilol holrs to gain access to the additional mounting points (Fig. 4). The plastic membrane covering the additional nut inserts is only 1 .Omm (0.040in) thick, and care must be tnkcn to cns\lrC that the nut inserts arc! ilol ci,~tri,igotl WIICII drilling AI, ;Itldition~il sol o f tlarnps ;Irld Ml, lot thr foirp spoke is avail,Ue IIO~TI your Aulollgltn stockist. CLUTCH LEVER 2 DRtVE MOTOR/GEARBOX Fig.6 DISHED WHEEL MOUNTING THE PEDESTAL BRACKET The pedestal bracket pin should be cut to length to suit the pedestal as follows: l Replace the wheel and measure the distance between the backplatc of ttre drive unit and the pedestal (dimension A Fig. 8). If the wheel is slightly bent, Fig.8 l Slide the wheel forward and place the pin end with the plastic cap in the slot (Fig. 10) DRIVE UNIT BACK PLATE l Fig.10 Remove the wheel and mark round the inside of the four holes. l Drill four 4.0mm (5/32in) diameter holes with the drill bit supplied (Fig. 12). Fig.12 SLOT METAL WHEELS To attach the drive unit to the wheel: l Place the drive unit with the clamping face uppermost i.e. drive motor and gearbox tube downwards. 0 Position one spacer at each of the three attachment positions (if the wheel is dished). 0 Remove the.wheel and place it on top of the drive unit making sure the face which is nearest the pedestal is downwards. l Place the clamps over the spokes and lightly tighten the bolts supplied (Fig. 7). Fig.7 FIXING BOLT SPOKE CLAMP 3 u the distance will change with the wheel position. The smallest distance should! be me,asured. The mounting pin should be cut 11 mm (0.40in) longer.than dimension A (Fig. 9). Fig.9 I*..`!? t """ )I CUT HERE PEDESTAL BRACKET PIN l Return the wheel to its normal position and with the pin mid-way in the slot, carefully mark round the bracket to record its position (Fig. 1 1). l \ DRIVE UNIT \ SPACER (IF REQUIRED) Attach the bracket and lightly tighten the screws. l Replace the wheel making sure the pin locates in the bracket. Turn the wheel to confirm the bracket is correctly positioned. If the wheel is slightly bent, or the wheel drive slightly off centre, the pin will move up and down in the slot of the backplate. Provided the pin does not reach the end of the slot this movement is acceptable. l Fully tighten all four screws. WOODEN WHEELS A separate attachment kit is available from your Autohelm stockist for use with wooden wheels (Catalogue number D119). A Remove any burrs and place the plast.*&, cap supplied over the cut end. CONTROL [JNIT The control unit (Fig. 13) slots into a permanently mounted socket sited in the cockpit. It contains a gimballed fluxgate compass and therefore has some restrictions on mounting position. The control unit should be sited where it can be operated easily from the steering position. It should also be positioned at least 80cm (2ft6in) away from the main steering compass to avoid deviation of both compasses. Deviation of the control unit fluxgate compass is less important since headings are always adjusted by reference to the main steering compass. Nevertheless, deviation should be avoided if possible and thus the control unit should be sited as far away from other magnetic or iron devices as practical. Having selected the best mounting site, the mounting socket may be secured to a vertical surface using the self tapping screws provided. Fig.13 ALTERNATIVE DRIVE UNIT MOUNTING POSITIONS The fluxgate compass is calibrated to give correct steering sense when' the drive motor is facing forward. If the steering wheel arlangement makes installation possible only with the motor facing aft, the motor drive sense will have to be corrected as follows. Use a screwdriver to rotate the changeover switch anti-cl+kwise until;' .) endstop is reached (Fig. 14). Never fot' the changeover switch, light pressud : only is required. CABLING AND POWER SUPPLIES , j (see Fig. 15) The four pin v+terproof connector provides a pluggable connection to the power supply and motor drive. Two terminals of the socket are prewired for connection to the 12v power supply, the drive unit cable is connected to the remaining two terminals on installation. It is most important that power supply is not connected to drive unit terminals. If the 12v supply is accidentally connected to the drive unit connection terminals permanent damage will be caused. For this reason the pre-wired power supply cable should not be removed from the socket. Before wiring the socket, select its position and drill a 22mm diameter hole. Pass the prewired power supply cable through the hole ready for connection to the battery. l-l DRIVE UNIT C ABI It (4.5m (151I)SUPPLIED) f1g.15 BATTERY CONNECTION The power supply cable is pre-wired to the socket and must be connected directly to the vessels electrical distribution panel. It must be independently switched and protected by a 15 amp fuse or current trip, and on no account paralleled into existing wiring for other equipment. The brown wire of the power supply lead should be connected to positive. If connections are accidently reversed the Autohelm 4000 will not operate but no damage will result. (SUPPLIED) FOUR PIN CONTROL CONNECTOR AND CABLE (SUPPLIED) : PO*ER SUPPLY CABL F (2m (HI) SUPPLIED CAB1.E CLIP (SUPPIUED) 12v SUPPLY (FROM DISTRIBUTION PANEI) (-.` ,f~~/-c~ \.--. -.---.-.-.,.~--..- -J CIRCUIT BREAKER AND 15A FUSE 6 Since the autopilot is microprocessor based it is very important that voltage losses in supply cables are minimised. Supply cables should therefore be as short as possible and of no less size than shown in the following table. Lead Length Up to 2.5m (8ft) Up to 4.0m (13ft) If it is necessary to extend the drive unit cable, the extensi.on should be as short as possible and of no less size than shown in the following table. Extension Cable Length Up to 2.5m (8ft) Up to 4.0m (13ft) WINDVANE ATTACHMENT The windvane attachment is normally mounted centrally on the after rail where it can be sited in clear wind on both tacks. The windvane mounting mast is clamped to the after rail by the two `U' bolts provided (Fig. 18j. The interconnecting cable should be brouqht throuqh the slot to allow the windvane head tobe plugged into the top of the mast (Fig.' 19). w- `"3e interconnectina cable can then be back and plugied into the Autohelm Note The windvane head is supplied with the vane detached for ease of packing. The vane is easily assembled to the head and secured by means of the circlip provided (Fig. 20). Care should be taken to ensure that the small circlio is ' correctly located in the groove. Copper Area ' 1 .5mm2 AWG 16 14 1 Copper Area 1 .Smm' 2.5mm' AWG 16 -----_- 2 5mm' 14 -_______- To avoid the risk of confusing the power supply and motor cables the power supply cabling should be completed before wiring the drive unit. DRIVE UNIT CONNECTION The drive unit is supplied with 4.5m (15ft) of two core cable which is passed through the pedestal or guard rail and connected back to the control unit socket as follows: l Drill 9mm (0.35in) diameter hole in.the front face of the pedestal. l Select one of the two grommets supplied and use it where the drive unit cable passes through the pedestal W3ll. Having attached the cable to the control unit socket, the socket may be screwed [n place using the four self tapping screws provided (Fig. 17). Fig.17 ' l l Rut1 the cable down the pedestal and sCcurC close lo the pedestal base using the clip provided. Run the cable back to the control unit socket (Fig. 16) and connect as follows: EARTH (Blue) \ POWER SUPPLY (Pre-wired at Factory) Fig. 16 DRIVE UNIT Accessory Connection The Autohelm 4000's accessories plug into the contrdl unit to facilitate stowing and servicing. To ensure reliable connection each plug incorporates a locking ring which should be turned clockwise to secure. The windvane should be connected \ .' the socket marked Vane and the hand'bd held remote to the socket marked Remote. . DRIVF UNIT CABI E (to be wired on installation) DRIVE UNIT (Blue to PIN 2) `PIN 3 (Brown) 8 OPERATION BASIC PRINCIPLES The following description of the Autohelm 4000's principle of operation will help you to make full use of its advanced features. The powerful combination of a fluxgate compass and microprocessor control provides "autolock" course selection together with precise push-button course adjustment. Deviation from the set course is continuously monitored by the sensitive fluxgate compass and corrective rudder is applied to return the vessel to course. The applied rudder is proportional to course error at any time and thus when the course is restored the rudder will be neutralised. When changes in vessel trim occur due to variations in wind pressure or engine throttle setting the course can only be maintained by the application of permanent rudder off-set (standing helm) to restore balance. If permanent rudder off-set is not applied to restore balance the vessel will bear on to a new heading. Under these circumstances the Autohelm 4000 detects that the original course is not being restored and continues to apply additional rudder off-set in the appropriate direction until the vessel returns to the original heading. Automatic trimming capability ensures that the originally set course is held irrespective of any changes in balance that may occur during the course of a passage. The Autohelm 4000's computer also continuously monitors the pattern of applied rudder correction and can distinguish unnecessary repetitive corrections caused by pitch and roll of the vessel from those necessary to maintain the selected heading. The computer will automatically neglect all unnecessary corrections so that autopilot activity and power consumption is continuously optimised at minimum levels. 10 ___-~-_--__--~-The hiqh deqree of control automation made possible-by the micio computer simplifies user control to a series df push bution operations. -.--- ~~_--. .--- ----f -` -1 -_. ...