(AP4S8 Rev 1) OPERATION AND INSTALLATION MANUAL.

Transcription

1 TMQ AP4 (AP4S8 Rev 1) OPERATION AND INSTALLATION MANUAL

2 Contents Contents... 2 Introduction...5 Warning...5 Overview...5 Autopilot Operation - Standard...7 Set (Standby)...8 Auto...8 Power Steering...9 GPS Waypoint Steering Watch Timer Mode...11 Commercial Boat Watch Timer...12 Autopilot Operation- Remote Control...13 Hand Remote Power Steer...15 Active Remote Auto Steer Active Remote Power Steer...16 Active Remote GPS Waypoint Steering...17 Steering Lever & Electric Helm Steering Jog Switch Steering...18 Sensitivity & Rudder Adjustments Counter Rudder Settings Alarms...23 Installation of Autopilot List of Components...25 Installation of Main Control Unit Installation of Compasses Installing a Compass-Top Sensor Installing a Magnetic Sensor Unit (Fluxgate Compass)...29 Fluxgate Compass Mounting Options Installation of Rudder Feedback Page 2 of 68

3 Precautions...33 Mounting...34 Selection Switch- Standard or Heavy Duty Feedback...35 Heavy Duty Rudder Feedback Installation Diagram...36 Standard Rudder Feedback Installation Diagram Installation of Remote Units NMEA Connection...40 NMEA Socket - Pin Configuration...40 GPS Data Input...40 GPS Data Input Connection...41 TMQ C-Plot Data Input Connection...41 TMQ Remote Display Connection Heading Data Connections...42 Heading Data Output Heading Data Output Selection Heading Data Input...43 External Alarm Installation...45 Wiring Connections AP4 Rear Panel...46 Examples - Drive Connection Diagrams...47 General Information - Drive Units Commissioning Checks Post Installation Checks...50 Pre Sailing Dockside Tests Sea Trials Rudder Limits Switch Setting...53 Compass Calibration TMQ Compass - COMMAG...55 Elproma Compass ECS Optional Extras...58 Circuit Page 3 of 68

4 Warranty Troubleshooting...67 Page 4 of 68

5 Introduction Warning AUTOMATIC PILOTS ARE DESIGNED TO BE A NAVIGATIONAL AID AND SHOULD NEVER BE LEFT SOLELY IN CHARGE OF THE VESSEL. AN ADEQUATE WATCH SHOULD BE MAINTAINED AT ALL TIMES. IT IS RECOMMENDED THAT THE AUTOPILOT NOT BE USED WHILE NAVIGATING IN RESTRICTED WATERWAYS AS WATER CURRENTS, WIND CHANGES OR RADIO TRANSMITTER INTERFERENCE MAY AFFECT VESSEL COURSE SUFFICIENTLY TO ENDANGER YOUR OWN OR OTHER VESSELS. Overview The AP4 autopilot is a rugged & reliable pilot for use on all sorts of vessels, motor or sail, commercial or pleasure. The front panel features large control knobs for ease of use in all sea conditions. It has various special modes of operation to cater for all different requirements. An AP4 system comprises the following essential components: Control Unit Compass or Compass-Top-Sensor Rudder Feedback Unit Rudder drive system Optional Components: Hand or active remote Second remote control display Steering lever or electric helm Rudder angle indicator External alarm Page 5 of 68

6 This autopilot can control the movement of the rudder through a mechanical drive motor, reversing hydraulic pump, solenoid valves on a constant running pump or relays. The motor outputs have been carefully designed to work with a wide range of motors - for more information, consult your dealer or TMQ Electronics. The autopilot unit should be installed out of direct sunlight and protected from water and spray. The compass must be installed in a place free of magnetic interference, and connected to the autopilot. The rudder feedback must be attached to the rudder in such a way that it can accurately measure the position of the ships rudder and is also connected to the autopilot. Provision has been made for two standard remotes, either hand remote or steering lever. Alternatively one active remote can be used. The special remote mode of operation may have to be adjusted for the various control devices. Extra devices may be connected via the internal connection strip, for example, GPS compass heading input. For more information on installation of your AP4 autopilot, see the Autopilot Installation section of this manual. For more information on using your AP4 autopilot, see the Autopilot Operation section of this manual. All control units operate on 12 or 24 volts DC. Electrical cables are supplied for interconnection of equipment. Hardware is supplied to mount and couple the mechanical drive unit into the steering system. Hydraulic installation kits can be supplied (optional at extra cost) if the pipe size and brand of hydraulic system is specified. Page 6 of 68

7 Autopilot Operation - Standard The following is a brief overview of the capabilities of the AP4 autopilot. Each is described in more detail later in following pages. Set/Standby Mode The digital display shows the current magnetic heading. The autopilot does not apply any steering corrections. Auto Mode The autopilot maintains your boat on the selected magnetic course. Course can be set or changed by rotating the Course knob or from a remote steering station. Power Steer The rudder may be controlled by the course knob on the main panel or from a remote steering station. GPS Mode When receiving information from a GPS unit, the autopilot can steer a vessel along a preset track to a precise latitude and longitude. Watch Timer A timer can be set from 1 to 120 minutes. When the time expires, an alarm sounds. Uses include timing of trawling runs or a reminder to check for anchor drag at set periods. Commercial Watch Timer For vessels under survey. The timer can be set to give a warning alarm at a fixed preset time and provide an output control signal for a loud external alarm 1 minute after the internal alarm sounds. (Note: External alarm piezo siren must be fitted) Page 7 of 68

8 Set (Standby) MODE switch in SET position The AUTO light is off The motor clutch is disengaged No steering control output is generated The digital display shows the vessels current magnetic course. Watch Alarm may be set (if required) Hand remote or steering lever (if installed) is ignored at first turn on. Other special remote modes are accessible (refer later) Possible alarm Watch timer alarm (if set) Auto Engaging Auto steering mode Rotate MODE switch to AUTO AUTO light is on Pilot is locked on to the course showing on display Steering control is generated Rudder can be driven to the limit set position Waypoint steering can be activated (if GPS available) Watch alarm can be activated. Disengaging the Autopilot Rotate the MODE switch to the SET position AUTO light is off Steering control is deactivated. Display shows boat heading Boat under manual steering control (helm) Page 8 of 68

9 Course Adjustment in AUTO Rotating the large course control knob (each "click" is 1º course change) Display shows course to steer after adjustment Each full rotation of course change knob gives 24º Possible alarms Off course (more than 45º) Watch timer (if set) Power Steering Engaging Power Steering Mode Rotate the MODE switch to the PWR position. AUTO light is on Display shows boat heading Boat is steered by rotating the COURSE knob Change course by rotating knob Note: The maximum amount of rudder which can be applied is controlled by Rudder Limit setting (see installation section). For information on Power Steering with a remote unit (eg: steering levers) see the section on remote units. Possible alarm Watch timer (if set) Page 9 of 68

10 GPS Waypoint Steering Autopilot must be interfaced to a GPS generating NMEA 0183 data output. A route has to be selected on the GPS (refer GPS manual). Engaging GPS Mode Switch MODE switch to AUTO Press GPS button (labelled with a satellite dish) GPS light will light Display changes to course to steer (BTW on GPS) Boat may change course to take up new course (maximum rate of turn is 10º per second) Disengaging GPS Mode Press the GPS button GPS light is out Pilot locks on to current heading of If no GPS data or AP4 does not receive the data Autopilot maintains lock on the current course No GPS data alarm will sound GPS light will flash Changing the mode switch to any position other than AUTO will also disengage the GPS mode. Setting up your GPS unit Consult your GPS manual for this procedure first. Because there are a great variety of GPS units that work with this autopilot, the following is a guide only. a) GPS must output NMEA 0183 data Page 10 of 68

11 b) Data must include at least one of the following sentences: (i) APA (ii) APB (iii) BOD and XTE. Set up route in GPS Set arrival zone Select auto sequence if more than one waypoint en route For XTE output only from GPS steer boat to course before engaging GPS on pilot.. Remember: Prior to engaging GPS you must program a route into the GPS for the autopilot to follow Watch Timer Mode To set pleasure boat watch timer Press TIMER button (labelled with a clock) Display reads time in minutes Rotate COURSE knob to set time required (max 120 minutes) Note: After 3 seconds the display reverts to boat heading To reset timer when alarm sounds When set time expires an alarm will sound Press TIMER button Time is reset to original time Note: If an external alarm is fitted, this will sound 1 minute after the internal alarm if the timer has not been reset or muted. To disable (mute) watch timer Press TIMER button Rotate COURSE knob until display reads 000 Press TIMER button again Page 11 of 68

12 Commercial Boat Watch Timer Used where survey regulations for commercial vessels require a watch timer (which includes an external alarm) fitted with an autopilot. NOTE: Once the commercial watch alarm has been enabled, it cannot be disabled by the user. To enable the commercial watch timer alarm Switch AP4 to SET mode. Hold down the GPS button and press TIMER button Display shows [900] Rotate COURSE knob until display reads [906] Press the TIMER button again Display shows [A-0] Rotate COURSE knob until display reads [A-1] Press the TIMER button Display shows [A00] Dial up Commercial Regulation Time, eg: for QLD dial [A05] Press TIMER button again Display then reverts to normal heading. Alarm will sound after set time has expired Press TIMER to reset When the commercial timer is enabled and the autopilot is in control of the boat (i.e.: in AUTO, GPS or REMOTE AUTO mode), the AP4 internal alarm sounds after completion of the selected interval and the louder external alarm one minute later, unless the timer is previously reset. In SET, PWR and remote POWER modes, the timer can be set to any required time as for a pleasure boat. Page 12 of 68

13 Autopilot Operation- Remote Control The following is a brief overview of the capabilities of the AP4 autopilot with remote control units. Each is described in more detail later in the manual. Hand remote The AP4 can be controlled with a hand remote unit. Auto and power steer modes can be selected. Special remote response mode r-1 must be set in AP4. Active remote The AP4 can be controlled with an active remote unit. Auto, Power Steer, GPS steering can be selected. Response and Rudder settings of AP4 can be adjusted. Special internal remote mode r-2 must be set Steering lever/electric helm The boat may be steered using a steering lever with the AP4. Special internal remote modes r-3, r-4, r-5 or r-6 must be set in AP4 depending on remote control connection. Jog lever The boat may be steered using a jog switch input with push button select switch. Special remote response mode r-7 or r-8 must be set depending on remote control requirements. Page 13 of 68

14 Hand Remote Auto Steer To engage auto steer mode with Hand Remote Unit Switch AP4 MODE to SET, AUTO or PWR Set remote knob to centre position Switch remote switch to AUTO Pilot locks on to boat heading as for normal autopilot Change course by +/- 90 º by rotating knob Note: If remote switch is already in the AUTO position, move switch to OFF and then back to AUTO. To disengage auto steer mode with Remote Unit Switch remote switch to OFF Pilot is now in SET mode Boat is now steered manually Note: When the autopilot has been "turned off" using a remote unit (eg: hand remote, etc), the MODE switch may be in the AUTO or PWR position BUT steering is under manual control (AUTO LED indicator would be off). To re-engage the autopilot, use the remote unit switch or move the MODE switch to SET then back to AUTO. Remote auto steering will also be disengaged by changing the position of the AP4 MODE switch Page 14 of 68

15 Hand Remote Power Steer To engage power steer mode with Hand Remote Switch AP4 MODE to SET, AUTO or PWR Set hand remote knob to centre position Switch remote switch to POWER STEER Boat is in power steer control Steer boat by rotating knob Note: If remote switch is already in the POWER STEER position, move switch to OFF and then back to POWER STEER To disengage power steer mode with Remote Unit Return remote unit course knob to centre Switch remote switch to OFF Pilot is now in SET mode Boat is now steered using helm The autopilot will return to SET mode. Page 15 of 68

16 Active Remote Auto Steer (AP4 must be set to r-2 special remote mode) To engage auto steer mode with Active Remote Unit Switch AP4 MODE to SET, AUTO or PWR Set remote knob to centre position Press AUTO on active remote AUTO LED on AP4 will light Pilot locks on to boat heading as for normal autopilot Change course by +/- 90 º by rotating knob To disengage auto steer mode with Active Remote Unit Press STANDBY on active remote Pilot is now in SET mode. AUTO LED is off Boat is now steered manually (by helm) Active Remote Power Steer To engage power steer mode with Active Remote Unit Switch AP4 MODE to SET, AUTO or PWR Set remote knob to centre position Press POWER STEER on active remote AUTO LED on AP4 will light AP4 display shows boat heading Boat can be steered by rotating active remote knob To disengage auto steer mode with Active Remote Unit Press STANDBY on active remote Pilot is now in SET mode. AUTO LED is off Boat is now steered manually (by helm) Page 16 of 68

17 Active Remote GPS Waypoint Steering To Engage GPS Mode Switch AP4 MODE switch to SET or AUTO Press GPS button on active remote GPS light on AP4 will light AP4 display changes to course to steer (BTW on GPS) Boat may change course to take up new course (maximum rate of turn is 10º per second) To Disengage GPS Mode Press AUTO button on active remote GPS light on AP4 light is out Pilot locks on to current heading of boat and is in AUTO mode Note: Active remote GPS control can also be deactivated by pressing STANDBY or POWER. For STANDBY the AP4 reverts to SET mode and the boat is steered manually (by helm). For POWER STEER the boat can be steered manually by rotating the active remote knob. Page 17 of 68

18 Steering Lever & Electric Helm Steering Note: AP4 must be set for the correct special remote mode (see page 60) Steering Levers and Electric Helms provide full follow up steering. A steering lever or electric helm operates in a similar way to a hand remote control. However, the method of operation will depend on the special remote mode set. To Engage Steering Lever or Electric Helm Press select switch (or toggle select switch) Steer boat using lever or wheel Note: Some internal remote mode settings allow for power steering at turn on. To disengage Steering Lever or Electric Helm Press select switch (or select new MODE on AP4) Steer boat manually Jog Switch Steering A jog lever is a device comprising a lever under spring tension for centre reference and two switches for bi directional control. With AP4 set for JOG input, a number of operations have been included in the software to extend the use of the AP4 control for some navigational situations (refer to selection of special remote mode 908, r-7 or r-8 on page 60) When special remote mode r-7 is set and the system is fitted with a jog lever and separate push button select switch, the boat can be steered using the jog lever either in AUTO JOG mode or POWER STEER JOG mode. Page 18 of 68

19 Jog Switch Steering with AP4 in SET Switch AP4 MODE switch to SET Press jog lever select button Boat is now in AUTO JOG under autopilot control Change course by using jog lever each jog switch movement gives 1º course change and a beep will sound For more rapid course change hold jog switch on course will change in 2º increments For POWER JOG press the selection switch Boat is now manually steered using the jog switch To return to AUTO jog press the selection switch again To toggle between AUTO JOG and POWER JOG press the selection switch. To exit JOG control switch the AP4 to OFF/AUTO/PWR Jog Switch Steering with AP4 in AUTO Switch AP4 to AUTO at initial switch on the system will operate in normal autopilot control; the jog lever will have no effect at this stage For POWER STEER JOG press jog lever select button Control rudder movement and direction by jog lever Manually steer the boat using the jog lever COURSE knob has no effect in this mode For AUTO JOG press jog lever select button Boat is now under autopilot control Change course by using jog lever each jog switch movement gives 1º course change and a beep will sound For more rapid course change hold jog switch on course will change in 2º increments Each successive press of the selection switch will toggle AP4 between POWER JOG steering and AUTO JOG steering To return to normal autopilot operation, switch the AP4 to SET then back to AUTO. Page 19 of 68

20 Sensitivity & Rudder Adjustments The AP4 autopilot has adjustments for setting heading sensitivity and rudder response to customise the boat for optimum steering performance. The control in the centre of the AP4 front panel adjusts both sensitivity and rudder ratio. The centre position is usually suitable for most vessels, but should the vessel's steering be sensitive or slow, adjustment maybe required. In general, a vessel with fast turning rate will require a small rudder response setting. A large, slow vessel may require a higher value for the rudder response. This may also be adjusted according to speed low speeds may require more rudder angle for steering than high speeds. Sensitivity This control adjusts the heading sensitivity (sometimes known as dead band) which varies the angular amount of heading change or wander allowed before the autopilot reacts to correct the change Rudder Ratio This control adjusts the rudder ratio which varies the amount of rudder applied for a course error. To adjust sensitivity Pull centre knob out Display will read a number eg: 05 Adjust the knob anticlockwise until pilot just begins to hunt (this is indicated by the port and starboard lights flickering) Turn knob clockwise until lights are not flickering. Push knob in Page 20 of 68

21 To adjust rudder ratio Ensure centre knob is pushed in Rotate centre knob Display will read a number eg: 06 Adjust knob until boat steers a straight course. Note the reading. Note: The sensitivity and rudder are normally adjusted together with sensitivity (knob out) being adjusted first, then rudder ratio. The sensitivity should be adjusted so that the AP4 is not continually driving back and forth (hunting) as this can prematurely wear your steering system If the centre knob is not pushed back in after the sensitivity is set, when 3 seconds has elapsed, the AP4 display will read rudder angle. When the rudder ratio setting is too low, turns will take an excessive amount of time, and the vessel may "wander". When the rudder ratio setting is too high, turns will be rapid and the vessel will oversteer. Experiment to find the best settings for your particular vessel. Only make small changes at a time. Page 21 of 68

22 Counter Rudder Settings The AP4 has a special internal mode for counter rudder setting. Special mode 913 allows the counter rudder settings to be turned on or off and the decay time to be set. The amount of counter rudder required can then be adjusted in the SET mode. This adjustment must only be made if the vessel requires counter rudder to steer. To set counter rudder Switch AP4 to SET mode Press GPS and TIMER buttons together Display reads 900 Adjust COURSE knob until display reads 913 Press TIMER. Display reads C00 Adjust COURSE knob until display reads C10 (divisor value) Press TIMER to set value. If set to C00, the counter rudder will be disabled. When adjusting, the lower the number, the slower counter rudder decay time will be. To adjust counter rudder Switch AP4 to SET mode Press GPS button Adjust COURSE knob to C08 (amount of counter rudder) The larger the number the greater the amount of counter rudder applied. The above settings are suggested values only and will differ from boat to boat. Note: The counter rudder is a compass heading change derived value. It cannot be simulated at the wharf. Testing should only be carried out in easy to navigate clear waters. Page 22 of 68

23 Alarms A number of conditions will cause alarms to sound. Each alarm has a different "beep pattern" (except watch timer and commercial watch alarm). The external alarm output may also be turned on by some of these alarms; this does not have a "beep pattern" but instead it sounds continually. Watch Timer Alarm This alarm indicates that the time set by the user has expired. Alarm pattern is 1 second on, 1 second off until reset. Commercial Watch Alarm (Option) This alarm indicates that the autopilot is in control of the vessel but timer key has not been pressed within the last five minutes (if set for 5 minutes). Alarm pattern is 1 second on then 1 second off until reset. The external alarm output is turned on 1 minute after the internal alarm begins to sound. Angle Off Course Alarm The alarm pattern is 0.2 seconds on, 0.2 seconds off when vessel is more than 45 degrees from course-to-steer. No GPS Data Alarm (Waypoint Steering) The alarm sounds 0.5 seconds on, 0.5 seconds off if the autopilot is not receiving valid information from the GPS. No Heading Reference (NMEA Heading or GPS Input) The alarm sounds 0.5 seconds on, 0.5 seconds off if the autopilot is not receiving heading data or GPS data for heading reference. Page 23 of 68

24 Installation of Autopilot EMC Considerations & Precautions:All TMQ equipment and accessories are designed to the best industry standard for use in the marine environment. Their design and manufacture conforms to the appropriate Electromagnetic Compatibility (EMC) standards, but good installation is required to ensure that performance is not compromised. Although every effort has been taken to ensure the autopilot will perform under all conditions, it is important to understand that some factors could affect the operation of the product. Installation instructions are provided in this manual. Some preliminary suggestions follow: Installation:To reduce the risk of operating problems, all TMQ equipment and cables connected to it should be at least 1 metre (3 feet) from any equipment transmitting or cables carrying radio signals, eg: VHF radios, cables and antennas. In the case of SSB radios, the distance should be increased to 2 metres (7 feet). TMQ cables should be used at all times. Cutting and rejoining these cables could compromise EMC performance and should be avoided unless doing so is suggested in the installation instructions. Position of electronic compass is important to ensure no magnetic interference. It may be necessary to trial several positions before deciding on an optimum position. Check other side of bulkhead, dash and/or deckhead for any material which may interfere with the compass (steel or iron in particular). Keep electronic compass away from the boat s magnetic compass. Page 24 of 68

25 Check:Always check the installation before going to sea to make sure that it is not affected by radio transmissions, engine starting, low battery voltage or other problems. In some installations it may not be possible to prevent the equipment from being affected by external influences. Usually this will not damage the equipment but may cause momentary incorrect operation. Interconnection:If your autopilot is to be connected to other navigational equipment using a cable not supplied by TMQ, a suppression ferrite should be fitted to the cable close to the TMQ unit. List of Components The AP4 Autopilot Control system when packed comprises the following: AP4 Main Control Unit 2 metre power cable Compass, Compass Top Sensor or Electronic Compass (depending on order) 5 metre cable attached Rudder Feedback Unit (RFUS)* 14 metre cable attached Rudder feedback linkage assembly Owners manual, mounting cradle & knobs, spare DIN plug for NMEA connection, mounting screws * May be RFUH with 14M cable not attached BEFORE INSTALLATION, ENSURE YOU HAVE PURCHASED THE CORRECT PARTS FOR YOUR VESSEL. Page 25 of 68

26 TMQ Autopilots are intended for use in three (3) basic configurations: AP4 can be used to control most brands of drive units or solenoid control valves (hydraulic). System components: Control unit Compass Rudder feedback unit AP4 and mechanical drive system - used to drive most handoperated mechanical steering systems eg: rod & chain, pushpull or pull-pull systems. Some helm pumps can also be used with a mechanical drive to provide an installation, which requires no additional hydraulic pump. System components: Control unit Compass Rudder feedback unit Mechanical drive 3. AP4 and reversing hydraulic pump - used with hydraulic steering systems. Different pump units are used to cater for a wide range of systems. Correct installation is required and pump size and voltage should be considered BEFORE installing the hydraulic pump. System components: Control unit Compass Rudder feedback unit Reversing hydraulic pump Page 26 of 68

27 Installation of Main Control Unit Position & mounting Select a dry position Provide access for wiring to rear of the pilot (minimum compass, feedback, power and drive) Install mounting cradle - on dash or suspended from deck head or cut out panel if mounting the pilot in dash Route the power cable to 12 or 24 VDC power source Check AP4 Mode switch is OFF Connect power cable to the AP4 Note: To control the autopilot from a remote position, fit a remote unit. Wiring Keep autopilot connection cables away from radio aerials and cables Select a drive unit interconnection cable of appropriate size to prevent voltage drop Page 27 of 68

28 Installation of Compasses There are three types of compass suitable for this autopilot - a compass-top sensor (TMQ CTS), a magnetic sensor unit ( TMQ fluxgate compass - COMMAG), or an electronic compass such as Elproma NMEA Compass (ECS1). Wiring The magnetic sensor unit or compass-top-sensor, which is supplied with your AP4 autopilot is fitted with a plug, which fits into the COMPASS socket on the rear of the autopilot. If the cable must be extended, we recommend that TMQ 5-core shielded extension cable be used. This is available from your supplier or TMQ Electronics. The Elproma compass cable is connected to the internal terminal strip marked T6 AUX - see Electronic Compass installation page 35. Installing a Compass-Top Sensor A compass top sensor should be used as the heading reference unit for steel boats. Before attaching the CTS to the top of a flat top compass, ensure there are no defects in the compass, eg: sticking card, as this will affect the operation of the autopilot. Position Firstly determine the correct position of the CTS on the compass glass top (CTS is central and cable facing aft) Route the cable to the AP4 control unit position Plug cable into AP4 compass socket Before fixing the CTS to the compass surface, switch on the AP4, align the CTS carefully so that the AP4 display reads the same as the boat magnetic compass When position is correct attach the CTS with double sided tape Page 28 of 68

29 Installing a Magnetic Sensor Unit (Fluxgate Compass) Where there is magnetic interference on a vessel, the magnetic sensor unit may have to be tried in several positions to obtain the best operating results before final installation. Good autopilot course holding is dependent upon the compass being free from magnetic interference Exercise care when handling the compass as internal gimbals may be damaged from abuse. Remove internal packing prior to installing. Position Determine a suitable position free of magnetic influence Ensure there are no radios or radio aerials or cables nearby Check other side of bulkheads or behind dashes for any likely interference Install compass bracket vertically (on bulkhead, dash or deck head) Carefully remove internal transit packing from compass Insert compass body into bracket Rotate compass in bracket until cable faces towards the stern Route the cable to the AP4 Control unit position Plug compass cable into AP4 autopilot Check AP4 display reads the same as the boat compass when pilot is switched on. Note: The compass can be mounted outside the hull of the boat if required (eg: on a mast of a yacht). However, places to be avoided are low in the hull near an engine or machinery because of magnetic interference or too high up a mast because of excessive movement. Page 29 of 68

30 Fluxgate Compass Mounting Options Calibration The compass is calibrated before leaving the factory and will be accurate if there is no external magnetic interference. After initial sea trials, you may wish to recalibrate the compass, although in most cases the factory calibration will be as good as or better than calibration achieved on the vessel. See the Compass Calibration Section. Page 30 of 68

31 Magnetic Sensor Unit & Compass Top Sensor Interchange The magnetic sensor unit (fluxgate compass) can be interchanged with a compass top sensor. This is desirable when the autopilot is to be fitted to a steel hulled vessel or vessel containing large amounts of steel. If the magnetic sensor unit and compass top sensor are interchanged, the compass detector DIP switches must be altered. The top cover of the AP4 has to be removed. The DIP switch is identified as component DIP1 on the PCB component overlay diagram at the rear of this manual. Both sections of the Switch OFF - for magnetic sensor unit (fluxgate) Switch ON - for compass top sensor Page 31 of 68

32 Installing an Electronic Compass Elproma ECS1 Note: Refer to Elproma installation instructions. Mount away from any external magnetic interference, eg: radio or speakers. The compass must be mounted in a vertical position with the arrow (on the top of the case) pointing towards the bow of the boat. Position Determine a suitable position free of magnetic influence Ensure there are no radios or radio aerials or cables nearby Check other side of bulkheads or behind dashes for any likely interference Install compass bracket vertically Rotate compass in the bracket if necessary until the arrow faces the bow of the boat Route the cable to the AP4 control position Connect the compass cable to the internal connection strip of the AP4 marked T6 AUX. Refer page 43. (Wiring colour code is also printed on the pcb at the left hand front of the AP4) Page 32 of 68

33 Installation of Rudder Feedback Precautions The rudder feedback unit is water resistant. However, if it is to be mounted in a wet position, some effort is necessary to ensure the unit does not become immersed in water. If necessary the standard rudder feedback unit may be mounted upside down, in which case the feedback cable must be cut in a suitably dry position, and the blue and red wires swapped. DO NOT MOUNT THE HEAVY DUTY RUDDER FEEDBACK UNIT UPSIDE DOWN NOTE: THE AUTOPILOT WILL NOT FUNCTION CORRECTLY IF A RUDDER FEEDBACK IS NOT FITTED, OR IF THE FEEDBACK IS FAULTY OR INCORRECTLY ADJUSTED. NOTE: THE RUDDER FEEDBACK UNIT IS FACTORY ALIGNED. THE ARM SHOULD NOT BE REMOVED OR LOOSENED UNNECESSARILY. IF ARM IS LOOSENED OR REMOVED, VOLTAGE ALIGNMENT SHOULD BE CHECKED BEFORE USING THE AUTOPILOT. THIS MUST BE DONE BY A COMPETENT TECHNICIAN. Page 33 of 68

34 Mounting Refer to the installation diagrams on pages 36 or 37 for the relevant rudder feedback unit. The rudder feedback unit is water resistant. However, if it is to be mounted in a wet position some protection will be necessary to ensure the unit does not become immersed in water. Position Select a position adjacent to the tiller arm Install the mounting bracket to accommodate the rudder feedback unit with its arm parallel to and pointing in the same direction as the tiller Attach the rudder feedback to the bracket. (For RFUS arm is uppermost. For RFUH shaft is lowermost) Drill a hole in the tiller arm for the linkage arm connection block (1/4 diameter) Attach the linkage swivel block to the tiller Attach the linkage ball joint to the rudder feedback arm Fit the linkage arm through the swive block and attach the other end to the ball joint Remove the top of the feedback (RFUH only) Connect 3 core cable to the RFU terminal strip (RFUH only) Route the rudder feedback cable to the AP4 position Connect the RFU cable to the RUDDER socket of the AP4 Installation Checks Turn the helm slowly from hard over to hard over and observe the movement of the rudder feedback arm Ensure the feedback arm or linkage does not foul in any position Ensure there is no strain on the feedback arm or linkage Page 34 of 68

35 Check the rectangular correlation between the feedback arm, the tiller and the linkage with rudder amidships Check direction of feedback arm movement (port and starboard) corresponds with the markings on the feedback body Check the feedback arm direction matches the tiller movement direction for port and starboard Note: Correct any problems before using the autopilot Selection Switch- Standard or Heavy Duty Feedback The AP4 is normally dispatched from the factory as ordered. However, when installation of the feedback is completed on the boat the RFUS / RFUH selection switch in the AP4 control unit should be checked for correct selection. If RFUS is used, set DIP 2 Switch 1 to OFF. If RFUH is used, set DIP 2 Switch 1 to ON. Note: DIP 2 Switch 2 is used for heading input with some AP4 software configurations. Normally set to OFF. Refer page 42. Page 35 of 68

36 Heavy Duty Rudder Feedback Installation Diagram Page 36 of 68

37 Standard Rudder Feedback Installation Diagram Page 37 of 68

38 Installation of Remote Units Hand and Active Remotes use a small clip bracket for mounting. Steering Levers are normally mounted in-dash. For a TMQ steering lever this will require a 90mm hole to be cut for mounting plus a position for a push button selection switch (if used). Other steering levers as required. The units are very robust and either of these may be mounted where it is subject to occasional splashes of water. If mounted in direct sunlight, the decal may fade. Hand Remote Select a position for the Hand Remote bracket Install the bracket and attach the remote Route the cable to the AP4 control position Plug the remote cable into REMOTE socket of AP4 When the AP4 is switched on, test the remote operation Active Remote Select a position for the Hand Remote bracket Install the bracket and attaché the remote Route the cable to the AP4 control position Plug the remote cable into REMOTE socket of AP4 When the AP4 is switched on, test the remote operation Steering Lever (TMQ) Select a position for the Steering Lever Cut a 90mm clearance hole for mounting the Lever Secure the steering lever with two screws Fit selection switch adjacent to lever (if used) Route the cable to the AP4 control position Plug the cable into the REMOTE socket at the rear of the AP4 Page 38 of 68

39 Remotes Calibration The remotes can be calibrated if required; this allows the full range of the steering input to be used. Each remote fitted has to be calibrated. Remote Calibration. (Carry out this procedure only after rudder limits have been set) Calibration Procedure Switch AP4 MODE switch to SET Press and hold pressed the GPS button Press TIMER button - display will read 900 Release both GPS and TIMER buttons Rotate COURSE knob until display reads 911 Press TIMER button - display now reads rcl Rotate each remote control knob in turn through full travel from port to starboard Press TIMER button to save settings and exit the procedure Note: If the boat does not steer straight ahead when the remote control course knob is centred, the rudder feedback may need realignment. Caution: If the boat is carrying temporary weather helm as a result of sail trim or net drag, realignment may not be necessary. Check BEFORE realigning.. Page 39 of 68

40 NMEA Connection The NMEA socket at the rear of the AP4 (internally labelled T4 DATA) allows for the following connections: 1. GPS data input for waypoint or GPS steering 2. TMQ proprietary data input and output data for TMQ remote display for example AP55 or AP VDC and 0 VDC power to remote display NMEA Socket - Pin Configuration Pin 1 GPS data positive input Pin 2 GPS data negative input Pin 3 TMQ data positive output Pin 4 Power negative Pin 5 TMQ data positive input Pin 6 Power positive RX+ RXTXD1 0 VDC RX2 10 VDC GPS Data Input The AP4 pilot will accept two forms of GPS data in NMEA 0183 format as follows: GPS Plotter data APA, APB or XTE+BOD for waypoint steering pilot display shows BTW GPS data as heading reference used when magnetic heading reference from a compass is not available pilot display shows COG * * Note: DIP2 switch 2 must be switched on to receive data for COG. Boat must be making more than 2 knots true speed over ground. Refer diagram on page 34. Page 40 of 68

41 GPS Data Input Connection Refer to GPS manual for correct identification of wires for data output connection. An example of GPS connection: GPS TX+ connect to AP4 RX+ (pin 1 of the NMEA Socket) GPS TX- connect to AP4 RX- (pin 2 of the NMEA Socket) TMQ C-Plot Data Input Connection The AP4 will accept data from a computer operation C-Plot program for waypoint steering. The connections are as follows: Pin 3 C-Plot Data Plug connects to pin 1 of the NMEA Socket Pin 5 C-Plot Data Plug connects to pin 2 of the NMEA Socket Displays shows bearing to waypoint - BTW TMQ Remote Display Connection When a TMQ remote display (AP55 or AP60) is used with the AP4, they have prewired plugs to connect to the NMEA socket. Provision is made for GPS or C-Plot data input via two wires attached to the plug as follows: GPS TX+ connects to the white wire (pin1 of NMEA socket) GPS TX- connects to the green wire (pin 2 of NMEA socket) Page 41 of 68

42 Heading Data Connections Heading Data Output Heading data output is available on the internal T6 connector strip pins 1 and NEG TX2 AA+ RXDRXD+ Negative and data return Heading data + out Output heading sentence type can be selected if required. Available options are: HDM, HDT or HDG individually or all three can be output together. Heading Data Output Selection Selection procedure. Switch AP4 MODE switch to SET Press and hold pressed GPS button Press TIMER button - display reads 900 Release GPS and TIMER buttons Rotate COURSE knob until display reads 912 Press TIMER button display reads S-1 Rotate COURSE knob for the required selection S-1 = HDM, HDT and HDG S-2 = HDM only S-3 = HDT only S-4 = HDG only S-5 = no output S-6 = no output Press TIMER button to save the setting and exit the procedure Page 42 of 68

43 Heading Data Input The AP4 pilot can accept NMEA 0183 heading data input from any source, for example, GPS compass or other electronic compass. TMQ is able to supply an electronic compass, Elproma ECS1, which will connect to the internal terminal strip T6. ECS1 Wiring Colour Code 1 NEG 2 TX2 3 A4 A+ 5 RXD6 RXD+ Link from NEG to RXD- Brown Purple No Connection Red Black Blue Brown to Black Heading data input from other external source (GPS Compass) Heading data input is connected to T6 pins 5 and NEG TX2 AA+ RXDRXD+ Receive data negative Receive data positive Heading Data Priority The AP4 is able to operate with both TMQ electronic compass (COMMAG) and NMEA heading data input connected. The pilot will accept the NMEA heading data as first priority. If the NMEA data is not present the AP4 will display the heading received from the standard compass (COMMAG - if fitted). Page 43 of 68

44 If the NMEA data fails during operation, the unit will revert to the standard compass and the alarm will sound. The alarm can only be cancelled by turning the AP4 off and on again. Page 44 of 68

45 External Alarm Installation For non survey vessels an external alarm is optional. For vessels needing the commercial watch alarm feature fitted for survey requirements, an external alarm is required in addition to the AP4 internal buzzer. This alarm will sound if the timer alarm has been sounding for one minute without being reset and autopilot is NOT in SET mode. A 12 volt piezo buzzer with current draw not exceeding 250 milliamps should be used (TMQ Part No. SIREN). If a siren or alarm unit is used which draws in excess of 250 milliamps, this should be connected via a relay. The external alarm circuit is used to energise the siren direct. For larger units the circuit energises a relay coil with the siren being energised via the relay contacts. To Install External Alarm Siren Mount SIREN in appropriate position for optimum effect (leads may have to be lengthened) Remove top cover of AP4 Connect SIREN + lead (red) to A+ terminal Connect SIREN lead (black) to ARoute siren wires through cut out at rear of AP4 Replace top cover of AP4 To enable the commercial watch alarm refer page 15. NOTE: Once the commercial alarm is enabled, it cannot be reverted. Page 45 of 68

46 Wiring Connections AP4 Rear Panel Motor Terminals Clutch + Clutch Motor A Motor A Power out to Clutch Normally High Switched to negative to operate Clutch Normally High, Switched to negative to drive Normally High, Switched to negative to drive NMEA In / Out GPS In GPS Return Data + Out to TMQ Display or PC Negative and Data - common Data + in from TMQ display or PC + 10 V out Remote Volts Wiper 1 Negative Control Line Remote 1 (High Power Steer, Low Auto) Wiper 2 Control Line Remote 2 (High Power Steer, Low Auto) Rudder Feedback Not used Negative Not used RFU Signal + 5 Volts to RFU Compass White Blue Red Yellow Green Blue Green Red / Brown (Square Wave Drive Signal) Page 46 of 68

47 Examples - Drive Connection Diagrams Page 47 of 68

48 General Information - Drive Units The AP4 autopilot is capable of controlling reversing hydraulic pumps, mechanical drives, linear hydraulic drive systems, linear mechanical systems, solenoid valves on constant running pumps and relays When installing any drive system, refer to the manufacturers specifications and instructions. Follow all instructions. Installation Considerations Mechanical Drives Ensure correct voltage of drive unit Mount horizontally in a dry position Ensure robust and stable mounting platform is available Provide for cable connection to AP4 control unit Provide access for drive sprocket and chain to be fitted Provide for cable lay if linear mechanical drive Check correct sprocket ratio for the boat Hydraulic Pumps Check correct pump voltage for boat Ensure correct flow rate of pump matched for steering Mount horizontally in a dry position Pump should be mounted lower then the helm pump Provide adequate space for hydraulic line connections Ensure access to existing boat steering lines A balance line must be connected from autopilot pump reservoir to helm pump reservoir Replace any vented bung on pump with non vented Check if extra lock valve is needed for steering system When mounted, fill with oil and purge air from system Page 48 of 68

49 Solenoid Valves Links are provided to allow jog lever operation in conjunction with AP4 S8 Autopilot. The links should be cut when connecting the AP4 for solenoid operation. When cut (open circuit) the autopilot control only pulls the drive outputs low. Positive voltage is supplied to the solenoid common connection. Links are marked J1 and J2 on the PCB. As preventative measure to ensure voltage spikes do not interfere with the autopilot or other equipment, spike suppression diodes should be fitted on solenoid valves. See example drawing page 46. Wiring Refer to manufacturer s connection diagrams. Keep connecting cables as short as possible and of sufficient size to avoid voltage drop along the cable length. Ensure all connections are tight. Recheck periodically. ALL CONSTANT RUNNING PUMPS SHOULD BE CONNECTED TO THE SUPPLY VIA AN ISOLATING SWITCH AND SUITABLE PROTECTION CIRCUIT FUSE OR CIRCUIT BREAKER Page 49 of 68

50 Commissioning Checks Post Installation Checks Check correct voltage is connected (12 or 24VDC) *. ENSURE POLARITY OF THE VOLTAGE SUPPLY IS CORRECT. Check compass and rudder feedback are plugged in Check remote units plugged in and GPS input connected (if fitted) Check drive unit cable is connected Check loose cables are clipped or tied up. Turn steering wheel fully clockwise and visually check that moving and mechanical parts do not foul Visually check that RFU arm has moved in the correct direction as indicated on the RFU label or top. Repeat step 7 & 8 for anti-clockwise wheel movement. * Voltage is determined by drive voltage requirements. Ensure pump is the correct voltage rating. Pre Sailing Dockside Tests Turn helm to mid ships position. Turn on main power supply. Set MODE switch to SET Check rudder limits adjust only if necessary. See Rudder Limits page 51. Determine vessel heading by a sighting on known heading or compass. Align autopilot magnetic sensor until display reads known heading. Select AUTO mode on control unit. Check AUTO light comes on. CAUTION: IF AUTOPILOT DRIVES HARD OVER, IMMEDIATELY TURN CONTROL UNIT OFF. Page 50 of 68

51 Reverse motor drive wires at terminal strip on rear of autopilot and repeat from Step Turn course knob 10 º to starboard. Green steering light should come on. Confirm that rudder moves to starboard. Turn course knob back to centre, then 10 º to port. Red steering light should come on. Confirm that rudder moves to port. NOTE: AT NO STAGE SHOULD THE AUTOPILOT DRIVE THE RUDDER INTO THE MECHANICAL STOPS. IF THIS IS ALLOWED TO HAPPEN, DAMAGE TO THE AUTOPILOT MAY RESULT 14. Set MODE switch back to SET position. Check Rudder Drive Speed The speed a rudder is moved by the autopilot drive unit will affect the steering responsiveness of the AP4. A rudder lock to lock time of approximately 15 seconds* is required for good course holding. *Note: Optimum rudder speed will vary between vessels. A larger ship or slower boat may require a slower speed. Rudder lock to lock angle is from 30º port to 30º starboard Switch AP4 in PWR Use a suitable timing device to check rudder speed Rotate control knob until rudder is fully to port Quickly rotate the control knob in starboard direction for a minimum of 3 turns. Time the rudder until it reaches starboard limit. Note the time. The autopilot is now ready for full operational testing and sea trial. Page 51 of 68

52 Sea Trials Basic Trial Sail the boat to an area of calm and open water Switch AP4 to SET Check compass headings against boat compass Carry out compass calibration if necessary see page 53. Note: It is rare for the AP4 heading and boat compass to agree exactly on every heading due to magnetic variations on the boat. When boat is underway switch AP4 to AUTO Observe steering adjust sensitivity and rudder response if required see page 22 and 23 Note: Good course holding is also affected by drive unit lock to lock times. If difficulty is experienced with course holding, check rudder drive speed. Between 10 and 25 seconds lock to lock should allow the autopilot to work successfully on most vessels. Additional Trials When basic trials have been satisfactorily completed, further trials can then be carried out on individual ancillary equipment where fitted, eg: hand remote, steering levers, GPS inputs, waypoint steering, etc. Check the operational sections of this manual for relevant functionality testing. Always use open waterways for testing until you are familiar with the operation. Page 52 of 68

53 Rudder Limits Switch Setting NOTE: THE RUDDER LIMITS ARE FACTORY SET TO 30 DEGREES. IF THE RUDDER FEEDBACK HAS BEEN INSTALLED CORRECTLY, THE P-L AND S-L SYMBOLS SHOULD DISPLAY WHEN THE RUDDER IS MOVED TO THE PORT OR STARBOARD LIMIT The rudder limits prevent the steering motor driving the rudder beyond its physical (mechanical) stops. The limits are set so that the limit display indicates before the rudder reaches the stops. There are two display symbols P_L (port limit), S_L (starboard limit) indicating the state of the rudder limit circuits: The port limit P_L display will come on when the rudder position is further to port than the limit set by the rudder limit port setting. This will cause any port drive command to be ignored and turn off the port drive light on the front panel. The starboard limit S_L functions in the same way for rudder angles to starboard. The display symbols do not appear when AP4 is in the SET mode. To Set Rudder Limits Switch AP4 to SET mode Hold down GPS button Press TIMER button - display shows 900 Rotate COURSE knob until display reads 905 Press TIMER button - display now shows rudder position as a scale of 0 to is centre rudder. Page 53 of 68

54 Rotate boat helm to required Port Limit Position (rudder should not have reached the stops) Check display reads between 000 and 110 (eg: 035) Press GPS button this sets the PORT LIMIT Rotate helm to required Starboard Limit Position Check display reads between 150 and 220 (eg: 220) Press TIMER button - this sets the STARBOARD LIMIT To check Rudder Limits Rotate MODE switch on AP4 to PWR Rotate COURSE knob anticlockwise (to port) until pilot stops driving rudder Visually check rudder has moved to required port limit position Rotate COURSE knob clockwise (to starboard) until pilot stops driving rudder Visually check rudder has moved to required starboard limit position Page 54 of 68

55 Compass Calibration The compass supplied with your AP4 autopilot has been calibrated during manufacture. This calibration will be satisfactory for almost all installations. If you have a steel vessel, or some other factor which causes the compass to perform poorly, the calibration procedure will adjust compass characteristics to compensate. The calibration should only be done if the compass is known to be inaccurate. If the AP4 compass displays a constant offset (eg the autopilot compass reads 3 degrees high on all bearings), simply rotate the AP4 compass case to align bearings with the ships compass. In this case it is not necessary to re-calibrate the compass as described on page 56. If the AP4 compass has inconsistent variation on different headings, the following calibration procedure can be carried out. This procedure should only be done in calm waters with adequate sea room. TMQ Compass - COMMAG Rotate MODE switch on AP4 to SET Press and hold pressed the GPS button Press TIMER button display should read 900 Release GPS and TIMER buttons Rotate COURSE knob until display reads 901 Press TIMER button Display should flash between CAL and current boat heading Turn the boat slowly through two complete circles in the same direction On completion of turns press and hold pressed GPS button Press TIMER button Release both buttons Rotate COURSE knob until display reads 902 Press TIMER button Display should revert to read normal boat heading Page 55 of 68

56 Note: If display shows res the calibration was invalid and the AP4 defaults to the factory setting. Repeat steps above to carry out calibration again. This completes the compass calibration. Check alignment of the AP4 compass by steering vessel due North (000 on ships compass) and, if necessary, rotate outer case of AP4 compass in its bracket until heading display reads 000. It is important to realise that on any vessel the ships compass can have heading errors as a result of the vessels magnetic signature. These errors can be minimised by having the ships compass swung and compensated by a licensed compass adjuster. Such adjustment should be repeated annually. In any case it is highly unlikely that the ships compass and autopilot compass will be congruent for every heading. If you are unsure of the success of the calibration, you may return to the factory calibration. To Reset Compass to Factory Calibration Switch MODE switch on AP4 to SET Press and hold pressed GPS button Press TIMER button display should read 900 Release both buttons Rotate COURSE knob until display reads 903 Press TIMER button Display will show res briefly before returning to normal heading. Elproma Compass ECS1 The Elproma compass is preset at the factory for automatic calibration. Do not calibrate an Elproma Compass. Page 56 of 68

57 AP4 Special Modes AP4 Special modes are internal settings which allow different operations to be performed by the AP4. Also, special modes allow certain parameters to be set which control the AP4 operation. To Enter Special Modes Switch AP4 to SET Press and hold pressed the GPS button Press TIMER button display reads 900 Release both buttons Rotate COURSE knob until required mode is shown on the display Press TIMER to exit the special modes Special Modes Display Selection Start compass calibration page 54 Store compass calibration page 54 Return to factory default calibration page 55 Factory test for calibration factory technician only Set limit switches page 52 Set commercial watch alarm page 12 Optional remote modes [r-1] = Basic remote [r-2] = Active remote [r-3] = Basic remote + power steer input on pin 5 [r-4] = Basic remote + power steer input on pin 5 in SET position [r-5] = Remote 1 input only Rem 1 pin 2 [r-6] = Remote input Rem 2 pin 5. Power Steer default at turn on [r-7] = JOG input with Select push button [r-8] = JOG input with Select push button + power steer in SET 911 Remote calibration page Heading data output selection page Counter rudder - page 22 Page 57 of 68

58 Optional Extras There are a range of optional extras that can be connected to the TMQ AP4 system as the need or circumstances require. Further information can be obtained from the TMQ website at Rudder Angle Indicator The rudder angle indicator is a flush mounted instrument providing a clear indication of rudder position, which is critical when docking or manoeuvring in close quarters. Electric Wheel The TMQ Electric steering wheel provides precise, light steering on any vessel with a power steering system installed. It simplifies vessel fit out by eliminating long hydraulic lines to the helm position Page 58 of 68

59 Hand Remote Active Remote Hand remotes and Active remotes provide the freedom to maintain full control of the autopilot and steering while moving around the vessel. Steering Levers These levers allow single handed control of any size vessel with power steering. Movement to port or starboard causes the rudder to follow proportionally. Reversible pumps Hydraulic pumps are available in 12 or 24 VDC with 1 or 2 litre capacities to suit all applications. Continuous pumps Constant running pumps available in 2 or 3 litre for 12 & 24VDC systems with accurate flow adjustment to set lock-tolock time. Page 59 of 68

60 Linear drives Single rod linear drives can be fitted to a wide variety of vessels. May be attached directly to the tiller or rudder quadrant. Mechanical drives 12 Volt DC mechanical drive unit to suit vessels with existing mechanical steering. Supplied with standard chain and socket. For 24VDC a 24/12 volt converter is used. Computer Software TMQ AP1000 Autopilot operating Software. Computer control program enabling autopilot control from a standard PC with serial COM ports. (Cable required) Page 60 of 68

61 Circuit

62 PCB Layout Page 62 of 68

63 Page 63 of 68