Raymarine SmartPilot S1000, Installation Manual

Page 1: ...SmartPilot S1000 Autopilot Installation Guide Document Number 87040 1 Date December 2004 87040_1 book Page 1 Wednesday December 22 2004 12 32 PM ...

Page 2: ... Systems with HC4600 HC4645 HC4647 HC4648 and HC4658 BayStar steering rams Systems with Hynautic K6 steering rams SeaTalk is a Registered Trademark of Raymarine All other trademarks used in this document are acknowledged Copyright Raymarine UK Limited 2004 Existing hydraulic steering system Buzzer Pump control S1000 Autopilot System S100 Remote Course computer Autopilot pump D7501 1 S100 REMOTE MO...

Page 3: ...ure the autopilot pump Fit the course computer 1 2 3 4 Fit miscellaneous items 5 Make electrical connections 6 Carry out post installation checks 7 In line power switch Buzzer Installation overview D7583 1 Page 9 Page 12 Page 16 Page 17 Page 18 Page 21 Page 28 S100 Remote 87040_1 book Page 1 Wednesday December 22 2004 12 32 PM ...

Page 4: ...d in a rational sequence but because of variations in boat design space available etc you may need to adapt the sequence to suit your particular circumstances Before you start fitting your S1000 Autopilot we recommend you Unpack your S1000 Autopilot and check that all parts are present PlanyourS1000Autopilotinstallationso thatyoufitthecomponentsin thebestpossible locations Important note The S1000...

Page 5: ...s Autopilot Pump Anti vibration mounts x 2 Course Computer Wrench 12 mm AF x 19 mm AF In line power switch Drill 3 4 mm Cable Tie x 10 D7330 1 S100 Remote 2 x cradles 1 pint 0 5 liter hydraulic fluid Belt clip assembly Fill cups Buzzer Parts supplied S100 REMOTE MODE STANDBY PILOT Ground lead Data cable Power cable Drain cups Lanyard 87040_1 book Page 3 Wednesday December 22 2004 12 32 PM ...

Page 6: ...uide D7331 1 Tools materials required Screwdriver No 2 Pozidriv Screwdriver medium flat blade Screwdriver small flat blade Countersink bit Pencil Drill Absorbent disposable wipes 87040_1 book Page 4 Wednesday December 22 2004 12 32 PM ...

Page 7: ... hoses are supplied in fixed lengths so there are some limitations on the positioning of the autopilot pump with respect to the boat s helm pump If you have internet access please view the installation video on lineat www raymarine com Before you disturb your hydraulic steering system we strongly recommend that you consult the manufacturer and read the steering system manuals 5 5 D7552 1 5 5 5 5 5...

Page 8: ...rp bends kinks or chafing of tube Locating autopilot pump Provide protection from physical damage Mount pump location either horizontally or with connector end up Do not mount pump with connector end down Install in a dry location Do not fit in engine compartments near fuel tanks or in any other area where fuel vapor is likely 87040_1 book Page 6 Wednesday December 22 2004 12 32 PM ...

Page 9: ...e third is a transparent low pressure hose The transparent hose is intended to help you check for air bubbles when bleeding the system and must be used only to connect the autopilot pump reservoir to the lower connector on the helm pump It must NOT be used anywhere else in the system Po rt Po rt B r e c S deel r i o v r e es R w Po rt Po rt B r e c S deel r i o v r e es R w 87040_1 book Page 7 Wed...

Page 10: ...s can disintegrate and the resulting particles can cause blockages in the hydraulic system CAUTION D7545 1 2 3 1 5 turns D7546 1 From hand tight use a wrench to tighten the joint a further 1 5 turns This should make it leakproof To change the orientation of the joint to align it with the hose further tighten the joint to a maximum of one further turn until the joint is facing the required directio...

Page 11: ...transparent hose is connected to the reservoir connector WARNING Do not allow hydraulic fluid to come into contact with your skin Wear the protective nitrile gloves provided when working with hydraulic fluid WARNING A sudden release of pressure from a hydraulic system could result in personal injury Before disconnecting any part of a hydraulic steering system safely release any pressure in accorda...

Page 12: ... a straight connector to the helm pump lower connector Connecting the autopilot pump sheet 2 D7483 1 5 Remove retain the plug from the helm pump lower port and drain the fluid into one of the cups provided Discard the drained fluid in accordance with local regulations 6 Label the port ram hose to aid future reassembly then disconnect both ram hoses straight connectors from the helm pump Remove ret...

Page 13: ...ctor at the helm pump lower connector This completes the connection of the autopilot pump Now bleed the steering system to steering ram Po rt Po rt B r e c S deel r i o v r e es R w D7484 1 Connecting the autopilot pump sheet 3 8 Connect hydraulic steering hoses from autopilot pump Port and Starboard connectors to the Port and Starboard connectors on the helm pump so that Port connects to Port and...

Page 14: ...topilot pump will introduce air into the steering system making it feel spongy and lumpy to operate To return the steering system to smooth operation use the procedure given here to bleed the air from the system P o r t P o r t B r e c S deel r i o v r e es R w Bleed procedure sheet 1 2 Loosen autopilot pump bleed screw 2 full turns 2 Top up helm pump with hydraulic fluid D7336 1 87040_1 book Page...

Page 15: ...erve the bubbles in the transparent tube Keep the helm pump reservoir topped up while doing this Keep turning the wheel counter clockwise until there are no more bubbles i e so the hydraulic fluid in the transparent tube is clear 3 Using a suitable screwdriver turn the autopilot pump shaft so that the flat on the shaft is toward the PORT side of the pump 87040_1 book Page 13 Wednesday December 22 ...

Page 16: ...in the transparent tube Keep the helm pump reservoir topped up while doing this Keep turning the wheel counter clockwise until there are no more bubbles i e so the hydraulic fluid in the transparent tube is clear D7337 1 5 Using a suitable screwdriver turn the autopilot pump shaft so that the flat on the shaft is toward the starboard STBD side of the pump 87040_1 book Page 14 Wednesday December 22...

Page 17: ...ure sheet 4 8 Turn the autopilot pump bleed screw fully clockwise and hand tighten it 7 Top up the hydraulic fluid 9 Replace the helm pump breather cap D7486 1 This completes the bleed procedure Now secure the pump Correct fluid level Helm pump 87040_1 book Page 15 Wednesday December 22 2004 12 32 PM ...

Page 18: ...vent damage to the mounting surface The autopilot pump should now be secure Now fit the course computer Po rt Po rt B r e c S deel r i o v r e es R w Securing the pump 1 2 Drill two 1 8 3 4 mm pilot holes for the fixing screws Place the pump at the intended location and mark holes for the fixing screws Po rt Po rt B r e c S deel r i o v r e es R w 87040_1 book Page 16 Wednesday December 22 2004 12...

Page 19: ...fixing screws Drill two 1 82 3 4 mm pilot holes for fixing screws Partially screw in the screws provided then slot the course computer onto the screws and tighten screws Countersink pilot holes to prevent damage to the mounting surface The course computer is now secure 87040_1 book Page 17 Wednesday December 22 2004 12 32 PM ...

Page 20: ...mm pilot holes 1 8 Secure the buzzer with the screws provided Countersink pilot holes to prevent damage to the mounting surface Locating Securing D7504 2 Fitting batteries in S100 Remote 2 x AAA batteries supplied When replacing use only high quality alkaline AAA size batteries 87040_1 book Page 18 Wednesday December 22 2004 12 32 PM ...

Page 21: ...Drill three 3 4 mm pilot holes for the fixing screws Fitting S100 Remote cradle Secure the cradle At fixed position On belt clip 1 8 Countersink the pilot holes to prevent damage to the mounting surface To separate cradle from clip Click 87040_1 book Page 19 Wednesday December 22 2004 12 32 PM ...

Page 22: ...otrusion on the switch barrel goes fully into the mounting hole 1 2 3 4 5 Cut inch 18 mm 11 16 1 5 Locating Securing Fit the in line power switch in an easily accessible location When all items have been fitted connect up the system electrics 87040_1 book Page 20 Wednesday December 22 2004 12 32 PM ...

Page 23: ...mp Data cable See Diagram B See Diagram B See Diagram C Diagram D See Diagram C See Diagram C Summary WARNING Before making electrical connections to any part of the S1000 system ensure the power source for the system is switched off In line power switch P o rt P o rt B r e c S deel r i o v r e es R w 87040_1 book Page 21 Wednesday December 22 2004 12 32 PM ...

Page 24: ...cting RF ground preferred method D7539 1 If the boat does not have a ground plate use the alternative method shown in the following diagram to connect the RF ground Now connect the power the autopilot pump Course computer POWER PUMP S1000 Autopilot Raymarine Ltd Portsmouth PO3 5TD England FCC ID PJ5S1000 IC 4069B S1000 0191 Product Code A18107 O 87040_1 book Page 22 Wednesday December 22 2004 12 3...

Page 25: ...s not have an RF grounding plate Do NOT connect the terminal to any other point D7540 1 Now connect the power the autopilot pump Course computer Product Code A18107 POWER PUMP S1000 Autopilot Raymarine Ltd Portsmouth PO3 5TD England FCC ID PJ5S1000 IC 4069B S1000 0191 Product Code A18107 O 87040_1 book Page 23 Wednesday December 22 2004 12 32 PM ...

Page 26: ...e Ltd Portsmouth PO3 5TD England FCC ID PJ5S1000 IC 4069B S1000 0191 Product Code A18107 O In line power switch 12 V Power supply Autopilot pump D7541 1 Course computer Diagram B Connecting power autopilot pump Now make the necessary Data Cable connections 87040_1 book Page 24 Wednesday December 22 2004 12 32 PM ...

Page 27: ...ourse Computer to a GPS using either of the following methods 1 To a Raymarine GPS via SeaTalk connections 2 To a Raymarine GPS via NMEA spur 3 To a non Raymarine GPS via NMEA spur External buzzer NMEA Spur Course Computer Data cable For details of the NMEA Spur connections refer to Diagram D Diagram C Connecting the Data Cable When connecting NMEA data from an external source always connect via t...

Page 28: ...onnector you can remove the connector and prepare the cable end as appropriate for your preferred method of connection Refer to the wire identification table below as necessary CAUTION Before making any changes to the Data Cable disconnect it from the Course Computer Pin 1 Pin 2 Pin 3 Pin 5 Diagram D NMEA connections If a Raymarine GPS such as the Raystar 120 or 125 is to be connected to the S1000...

Page 29: ...nstallation Guide 27 This completes the installation procedure Now carry out the Post installationprocedures below POWER PUMP D7551 1 Course Computer Secure wires 87040_1 book Page 27 Wednesday December 22 2004 12 32 PM ...

Page 30: ...eering system To do this use the purge procedure at the following web address http www seastarsteering com OUTBOARD oboard htm FILL_PURGE FillPurge htm 1 Checking for leaks Checking for leaks sheet 1 Ensure all hydraulic joints are secure then turn the wheel to port When the hard over point is reached continue turning to port to pressurize the port lines until the safety valve releases At this poi...

Page 31: ...fluid leaks 5 D7550 1 With the starboard lines at maximum pressure check the starboard lines for leaks paying particular attention to the joints If a leak occurs turn the wheel to port to release the pressure then repair the leak and repeat step 3 4 Turn the wheel to starboard and when the hard over point is reached continue turning to starboard to pressurize the starboard lines until the safety v...

Page 32: ...PACE is required in front of your boat Do NOT start Autolearn unless this space is available 1 Before you use the autopilot run the inbuilt Autolearn facility to set up the autopilot for your boat At the S100 remote hold down STANDBY for 2 seconds to enter Pilot Setup mode 2 Press MODE the necessary number of times to display AUTOLEARN 3 Press PILOT to initiate Autolearn Pilot Setup AUTOLEARN CLEA...

Page 33: ...learn process takes from 7 to 27 steps 6 At the end of a successful Autolearn process the display shows LRN PASS When this occurs hold down STANDBY for 2 seconds to save the Autolearn values and enter autopilot Standby Mode If an Autolearn process fails the display shows LRN FAIL Press and release STANDBY to return to Autolearn and repeat the process LEARNING STEP 1 LRN PASS LRN FAIL 87040_1 book ...

Page 34: ...32 S1000 Autopilot Installation Guide 87040_1 book Page 32 Wednesday December 22 2004 12 32 PM ...

Page 35: ...lk NMEA 0183 S100 Remote Voltage 3 V supplied by two internal AAA batteries Dimensions S100 Remote only 101 mm x 60 5 mm x 35 mm Remote in cradle 103 mm x 66 mm x 44 mm Waterproofing IPX 6 Hydraulic fittings Tapered thread NPT National Pipe Thread Hose connection thread 9 16 UNEF Unified Extra Fine Hydraulic fluid Recommended Types Canmet Steering Fluid High VI ISO 15 Hydraulic Oil SeaStar BayStar...

Page 36: ...given heredescribetheconditions for optimum EMC performance but it isrecognized that itmay not be possible to meet all of these conditions in all situations To ensure the best possible conditions for EMC performance within the constraints imposed by any location always ensure the maximum separation possible between different items of electrical equipment For optimum EMC performance it is recommend...

Page 37: ...ine equipment Always use the ferrites supplied by Raymarine Connections to Other Equipment If your Raymarine equipment is to be connected to other equipment using a cable not supplied by Raymarine a suppression ferrite MUST always be attached to the cable near the Raymarine unit D3548 6 87040_1 book Page 35 Wednesday December 22 2004 12 32 PM ...

Page 38: ... USA Tel 1 603 881 5200 Fax 1 603 864 4756 www raymarine com Raymarine UK Ltd Quay Point Northarbour Road Portsmouth Hampshire PO6 3TD United Kingdom Tel 44 0 23 9269 3611 Fax 44 0 23 9269 4642 www raymarine com 87040_1 book Page 36 Wednesday December 22 2004 12 32 PM ...