Raymarine 150G, Service Manual

Page 1: ... installation or setting to work carries the European CE mark only parts and components supplied or approved for such use by Raymarine should be used in order to maintain compliance with the relevant CE requirements Incorporation use or attachment by any means of parts or components not supplied for or not approved for such use by Raymarine or if supplied or approved for use by Raymarine not prope...

Page 2: ...T150 150G T400 400G Course Computers 2 Type 150 150G 400 400G Course Computers Service Manual 83156 1 Type 150 400 Course Computers Service manual contents Raymarine Ltd 2002 ...

Page 3: ...Resistors 16 Relay Visual Checks 16 FET SIL Pad 16 3 3 Detailed Diagnosis 17 Step 1 Power Checks 17 Step 2 System Checks 19 Step 3 Rate Gyro if fitted 19 Step 4 Compass 20 Step 5 Rudder Reference 21 Step 6 Clutch Auto 21 Step 7 Clutch Standby 21 Step 8 H Bridge 22 Step 9 NMEA 22 Step 10 Kill Switch 23 Step 11 EEPROM Test 23 Chapter 4 Disassembly and Reassembly 24 4 1 Tools required 24 4 2 Disassem...

Page 4: ...30 NMEA Output 30 SeaTalk 30 Microcontroller 30 Watchdog 31 Flash Memory Programming 31 Non Volatile Memory 31 Chapter 6 PCB Details 32 6 1 Inputs and outputs 32 6 2 Circuit diagram and PCB layout 33 6 3 PCB components 34 Type 150 150G 400 and 400G surface mount 34 Type 150 150G conventional mount 37 Type 400 400G conventional mount 38 Chapter 7 Software Upgrade 39 7 1 Introduction 39 7 2 Minimum ...

Page 5: ...T150 150G T400 400G Course Computers Type 150 150G 400 400G Course Computers Service Manual 83156 1 5 Type 150 400 Course Computers Page intentionally left blank ...

Page 6: ...core pack 12 V All Raymarine Type 1 12 V drives and pumps including 12 V Constant Running pump No Type 150G E15015 E12091 core pack 12 V All Raymarine Type 1 12 V drives and pumps including 12 V Constant Running pump Yes Type 400 E15014 E12055 core pack 12 V or 24 V All Raymarine 12 V and 24 V Type 1 Type 2 and Type 3 drives and pumps Drive voltage must be matched to boat s supply voltage No Type ...

Page 7: ... 150G 400 and 400G 5 Socket screw M4 x 8 x4 6 Main cover 7 EMC washer x4 150 400 PCB fittings kit pack A18068 5 Socket screw M4 x 8 x3 8 Hexagon pillar M4 x 30 x4 9 Cup washer x2 10 Pozi screw M4x16 x4 11 Spring washer M4 x2 12 FET clamp x4 15 FET pad 16 Insulation spacer 150 PCB assembly pack A18066 9 Cup washer x2 13 150 PCB sub assembly 15 FET pad 16 Insulation spacer 150 FET pack A18070 14 FET...

Page 8: ... Fuse puller 3 Spare fuses 4 Label main cover 5 Socket screw M4 x 8 x7 6 Main cover 7 EMC washer x4 8 Hexagon pillar M4 x 30 x4 9 Cup washer x2 10 Pozi screw M4 x 16 x2 11 Spring washer M4 x2 12 FET clamp x2 13 Type 150 150G PCB assembly 14 FET 1RFZ48N x2 15 FET pad 16 Insulation spacer 17 Heatsink base Type 150G only 18 Socket screw M3 x 12 x2 19 Standoff pillar x2 20 GyroPlus yaw sensor 12 x2 13...

Page 9: ...PCB fittings kit pack A18068 5 Socket screw M4 x 8 x3 8 Hexagon pillar M4 x 30 x4 9 Cup washer x2 10 Pozi screw M4x16 x4 11 Spring washer M4 x2 12 FET clamp x4 15 FET pad 16 Insulation spacer 400 PCB assembly pack A18067 9 Cup washer x2 13 400 PCB sub assembly 15 FET pad 16 Insulation spacer 400 FET pack A18071 14 FETs IRF3205 x4 15 FET pad 16 Insulation spacer 150 400 Rate Gyro pack A18069 7 EMC ...

Page 10: ...are fuses 4 Label main cover 5 Socket screw M4 x 8 x7 6 Main cover 7 EMC washer x4 8 Hexagon pillar M4 x 30 x4 9 Cup washer x2 10 Pozi screw M4 x 16 x4 11 Spring washer M4 x4 12 FET clamp x4 13 Type 400 400G PCB assembly 14 FET IRF3205N x4 15 FET pad 16 Insulation spacer 17 Heatsink base Type 400G only 18 Socket screw M3 x 12 x2 19 Standoff pillar x2 20 GyroPlus yaw sensor 10 x4 11 x4 12 x4 14 x4 ...

Page 11: ...s packs for 150 150G 400 400G Type 150 400 Connector Cover A18064 D5581 1 Fastener stud and receptacle Connector cover 4A auto fuse 5A auto fuse 30A auto fuse 40A auto fuse Fuse puller Type 150 400 Fuse Pack A18065 D5582 1 Type 150 400 Main Cover A18063 M4 x 8 Cap Socket Screw x4 Main cover EMC Washer x4 Labels 150 150G 400 400G D5583 1 ...

Page 12: ...rse Computers Type 150 400 PCB fittings A18068 D5584 1 M4 x 30 hexagon pillars x4 M4 cup washer x2 FET pad Insulation spacer FET clamp small x4 M4 spring washer x4 M4 x 16 pozi screws x4 M4 x 8 cap socket screws x3 Type 150 PCB assembly A18066 D5585 1 M4 cup washer x2 Type 150 PCB sub assembly FET pad Insulation spacer ...

Page 13: ...156 1 13 Type 150 400 Course Computers Type 400 PCB assembly A18067 D5586 1 Cup washer x2 Type 400 PCB sub assembly FET pad Insulation spacer Type 150 FET pack A18070 D5587 1 FET pad IRFZ48N FET x4 Insulation spacer Type 400 FET pack A18071 D5588 1 FET pad IRF3205N FET x4 Insulation spacer ...

Page 14: ...1 Type 150 400 Course Computers Type 150 400 Rate Gyro A18069 D5589 1 FET pad Insulation spacer M3 x 12 cap socket screw x2 Standoff pillar x2 GyroPlus yaw sensor with attached insulator EMC washer x4 Type 150 400 Cable Clamp A18072 D5590 1 Cable clamp strip with assembled clamp seal Reusable cable tie ...

Page 15: ...re a larger PSU 10A to cope with the inrush during start up A conventional 330 Ohm resistor rated at 1 Watt to use as a clutch load R66 can be removed from a scrap Course Computer PCB and used for this purpose A 3mm Allen Key to remove the Course Computer cover 3 2 Initial Inspection Checks Before applying power to the Course Computer carry out following visual inspections Remove the top cover of ...

Page 16: ... Rate Gyro Connection The plug is designed to fit one way into the socket Ensure that the keyed side of the plug faces the outermost side of the PCB when inserted There are matching slots in the socket to accommodate this Red Yellow Black D6101 1 Relay Visual Checks The relay RL1 on the Course Computer PCB can carry up to 40A but if for any reason it does not close this will cause DX to fail Check...

Page 17: ...he right hand side of the PCB 3 3 Detailed Diagnosis Before starting testing ensure that the following are connected to the Course Computer Fluxgate compass Rudder reference Control Head 330Ohm resistive load to the clutch terminals Pathfinder Display connected via NMEA 1 do not connect the Pathfinder unit via SeaTalk Unless otherwise stated the following tests should be carried out with 12V appli...

Page 18: ...rs Only Apply 24V to the Course Computer Check that the following voltages are correct Testpoint Measured Voltage Type 400 VPWR 24V V12 13V 3V 3 3V 5V 4 9V 5 2V VIN 12V 35 36V VADC If all the voltages are correct proceed to Step 2 If any of these voltages are incorrect return the Course Computer to your nearest Raymarine Service Center with the results of these tests ...

Page 19: ... T150G or T400G it is necessary to test whether the internal rate gyro is functioning correctly Using a Digital Voltmeter set to measure DC measure the voltage at the rate gyro terminals on the front connector strip If the rate gyro is serviceable the reading should be between 2 1V and 2 9V If the voltage is within these limits proceed If the compass display does not match the change in orientatio...

Page 20: ...ECK COMPASS Hold compass with the cable protruding downwards and rotate by 90º Check control head compass display recognises change Repeat until compass spun through 360º Note Ensure that you hold the compass with the cable protruding downwards Slowly rotate the compass clockwise through 360º As the compass is turned check that the displayed heading increases with no sharp changes in the reading I...

Page 21: ...e right way proceed to Step 6 If the rudder bar display moves the wrong way o turn off the power o reverse the red and green wires connected to the RUDDER inputs on the Course Computer o switch on the power and re check If the rudder bar is still not working correctly return the Course Computer and Rudder Reference Unit to your nearest Raymarine Service Center Step 6 Clutch Auto Ensure that the ru...

Page 22: ...ect proceed to Step 9 Otherwise return the Course Computer to your nearest Raymarine Service Center Step 9 NMEA Receive Enter a new waypoint into the Pathfinder unit Perform a Goto Waypoint command on the Pathfinder Unit Verify that the waypoint information has been sent to the Course Computer by viewing the XTE DTW and BTW data pages on the Control Unit Transmit Check that the heading displayed o...

Page 23: ...ks that the calibration settings are being stored correctly Using the calibration screens change the Drive Type to another value and make a note of this new value Save the setting and exit calibration Cycle the power to the unit Verify that the drive type has not changed from the value set above Repeat the above If the Course Computer retains the settings as described then these tests are complete...

Page 24: ...main cover screws 5 2 Remove the main cover 6 and connector cover 1 Make sure that the 4 EMC washers 7 are retained on the underside of the main cover 3 Unscrew the FET clamp screws 10 and then remove the screws washers 11 and FET clamps 12 Note Type 150 150G PCBs have 2 FET clamps screws washers Type 400 400G PCBs have 4 FET clamps screws washers 4 To remove the PCB unscrew and remove the 4 hexag...

Page 25: ...eft of the PCB 3 Unscrew and remove the 2 GyroPlus screws 18 and standoff pillars 19 4 Remove the GyroPlus yaw sensor 20 and attached insulation pad Fitting the GyroPlus yaw sensor 1 Position the GyroPlus yaw sensor 20 under the PCB 13 2 Fit the 2 standoff pillars 19 and GyroPlus screws 18 and tighten the screws to secure the sensor to the PCB 3 Plug the GyroPlus connector into the socket on the P...

Page 26: ... on PCB There are seven test points available on the Course Computer PCB These are VPWR Incoming Supply Voltage 12V or 24V V12 12V Systems Incoming Supply 24V Systems Regulated to 12V DC 3V 3 3V DC Rail Voltage Used by Microprocessor 5V 5V DC Rail Voltage VIN 12V Approx 12V above VPWR for high side FET drives VADC Regulated 6 9V DC for ADC conversion in fluxgate circuit 0V Ground D6081 1 ...

Page 27: ...n the Type 150 Course Computers only and connects the incoming supply directly to rail V12 The following switch mode regulator components are not fitted on Type 150 Course Computers Inductors L43 and L1 Diodes D7 and D9 Switch Mode Regulator IC3 Capacitors C121 C122 C123 C13 C18 and C21 FET TR8 On Type 400 Course Computers the feed to V12 is switched via FET TR8 from either the incoming supply or ...

Page 28: ...se to the WATCHDOG RESET or KILL signals going low The buffers in IC24 and transistors TR80 TR49 and TR50 control this The H Bridge provides direction and speed control of the motor Speed control is achieved by modulating the drive voltage at 20KHz for various duty cycle settings Spool Valve Control Both the Type 150 and 400 Course Computers have dedicated ground connections for use with solenoid ...

Page 29: ...ctly from 5V ANA The output and external gyro are connected to the same part of the circuit This makes the output of the internal gyro available for direct measurement for diagnostic purposes at the Yellow terminal of the external gyro connector block In either case external or internal gyro the signal is buffered by voltage follower amplifier IC13d The difference between this signal and a 2 5 Vol...

Page 30: ...rive levels to comply with NMEA 0183 requirements SeaTalk The SeaTalk circuit is a complex bi directional buffer stage which provides level shifting and drive capability for both transmit and receive This is in addition to isolation capability in the event of fault conditions FET TR68 prevents the Course Computer being back powered from an external voltage on the SeaTalk Red bus Fuse FS2 limits th...

Page 31: ...signal WATCHDOG to go low This Output signal is fed into the H Bridge control logic to shut it down in the event of any problem occurring Link LK3 normally not fitted connects capacitor C67 to the 5V DIG power rail keeping it charged at all times This is used for diagnostic purposes only Flash Memory Programming FET TR72 is used to connect the VPP programming voltage pin of the microcontroller to ...

Page 32: ...k Color label Signal Direction 1 POWER Nominal 12 V or 24 V DC IN POWER 0 V IN 2 OFF SWITCH Switch contact 1 IN OFF SWITCH Switch contact 2 IN 3 MOTOR A Motor A OUT MOTOR B Motor B OUT 4 FLUXGATE gray Compass drive 2 OUT FLUXGATE red VRESET OUT FLUXGATE green Compass output F GA IN FLUXGATE yellow Compass output F GB IN FLUXGATE blue Compass drive 1 OUT 5 NMEA 1 NMEA 1 In IN NMEA 1 NMEA 1 In IN 6 ...

Page 33: ... NMEA 2 NMEA 2 In OUT 15 SPARE 0 Not currently used TBA 400 400G only SPARE 1 Not currently used TBA SPARE 2 Not currently used TBA SPARE 3 Not currently used TBA 16 SPARE 4 Not currently used TBA 400 400G only SPARE 5 Not currently used TBA SPARE 6 Not currently used TBA 17 SPARE 7 Not currently used TBA 400 400G only SPARE 8 Not currently used TBA SPARE 9 Not currently used TBA 6 2 Circuit diagr...

Page 34: ...K MNR14 1 RN26 91122K2 RES NETWORK 2K2 MNR34 2 RN22 RN25 91124K7 RESISTOR NETWORK 6 RN10 RN17 RN21 RN24 RN27 RN28 91AAAXX100K RES 100K 1 0 063W 0603 5 R118 R138 R222 R65 R67 91AAAXX100R RES 100R 1 0 063W 0603 9 R15 R174 R247 R256 R271 R277 R279 R303 R45 91AAAXX390R RES 390R 1 0 063W 0603 1 R156 91AAAXX470K RESISTOR 470K 1 0603 3 R253 R261 R29 91AAAXX470R RESISTOR 470R 1 0 063W 0603 2 R243 R244 91A...

Page 35: ...OR 0 01uF X7R 2 C167 C7 93070U1 CAPACITOR 1uF 1206 34 C135 C140 C141 C142 C143 C146 C149 C152 C165 C175 C179 C19 C25 C34 C35 C42 C43 C47 C48 C54 C56 C57 C58 C62 C63 C64 C65 C66 C68 C73 C82 C87 C91 NAL C180 93091U CAPACITOR 1uF TANT 2 C16 C17 93102U2 CAPACITOR 2 2uF 1 C53 931122U CAPACITOR 22U 6V3 TANT 3 C156 C72 C83 9324100U CAPACITOR 100uF ELECT 6 3VDC 3 C102 C112 C55 932410U CAPACITOR 10uF 16VDC...

Page 36: ...R28 TR33 TR36 TR40 TR59 9500BC817 BC817 18 TR37 TR41 TR42 TR55 TR60 TR61 TR65 TR66 TR70 TR71 TR73 TR78 TR80 TR81 TR82 TR83 TR84 TR85 9500IMT1 DUAL TRANSISTOR ARRAY 2 TR45 TR57 9500IMX1 DIGITAL TRANSISTOR ARRAY 18 TR1 TR10 TR12 TR19 TR2 TR21 TR26 TR31 TR43 TR48 TR49 TR50 TR53 TR67 TR69 TR7 TR74 TR75 9500IMZ1 DUAL TRANSISTOR ARRAY 1 TR51 9600CHIPIND3 CHIP FILTER BLM41P800S 1 L49 9600CHOKE2 INDUCTOR ...

Page 37: ...C160 C161 C3 C4 03174 CAPACITOR 33uF 50V AL ELECT 1 C28 03175 CAPACITOR 82uF 35V AL ELECT 1 C29 03177 CAP AL ELECT 1000uF 50V 1 C33 03179 CAPACITOR 4700nF 50V POLY 2 C1 C2 05007 TRANSISTOR TIP31A 1 TR3 05040 FET IRFZ48N TO220 PACKAGE 6 TR18 TR24 TR27 TR34 TR56 TR68 07375 TERMINAL BLOCK 28 1 TBA 07392 2 x 25 WAY HEADER AMP 1 HD1 07397 PCB TERMINAL BLOCK 2 TB1 TB3 07399 PCB CONNECTOR DBC 2 2 5 3 T 1...

Page 38: ...50V AL ELECT 1 C28 03175 CAPACITOR 82uF 35V AL ELECT 1 C29 03176 CAP POLY 10nF 63V 2 C129 C130 03177 CAP AL ELECT 1000uF 50V 5 C121 C122 C123 C13 C33 03178 CAPACITOR 470pF 100V POLY 2 C119 C120 03179 CAPACITOR 4700nF 50V POLY 3 C159 C1 C2 04080 REGULATOR LT1270ACT FLOW 06 1 IC3 05007 TRANSISTOR TIP31A 1 TR3 05040 FET IRFZ48N TO220 PACKAGE 2 TR56 TR68 05060 MOSFET IRF3205 POWER FET 5 TR18 TR24 TR27...

Page 39: ...T 4 0 This chapter describes the upgrade procedure 7 2 Minimum Requirements PC with an Intel 486 CPU and 16650 UART refer to your PC s handbook The three program files should be installed on a local hard disk 7 3 Connecting the Course Computer to the PC Power off the Course Computer and connect a cable as shown to the PC s serial port The connection of both NMEA ve ports to ground is essential Typ...

Page 40: ...nd black TX CMD null messages scrolling down the screen 7 Make sure that every other line is a red ACK as shown above If it is not power off the Course Computer and then power it on again 8 Select DOWNLOAD from the top menu and click on DOWNLOAD APPLICATION 9 A new dialog box will appear and you will need to select the appropriate BIN file to be used 10 DO NOT SWITCH OFF POWER TO THE COURSE COMPUT...