AFS Pilot Series Autopilots
Contents
1. P101 Function Notes Pin 1 Pitch servo reversal circuit 2 Pitch servo reversal circuit Install jumper between pins 1 amp 2 to reverse pitch servo direction If jumper is already installed between pins 1 amp 2 cut it to reverse pitch servo direction 3 Control Wheel Switch Connect as shown in wiring diagram to a SPST momentary switch located remotely to the autopilot for convenient engage disengage function 4 Pitch Servo Torque Control A signal from the autopilot to the pitch servo which sets the amount of torque to be delivered by the servo 5 Pitch Servo Trim Sensor A signal from the pitch servo to the autopilot which indicates an out of trim condition and its direction 6 Autopilot Master 12 to 28 V DC The autopilot itself draws less than 0 5 ampere Most of the current required by the autopilot system is used by the servos up to 2A per servo 7 Auxiliary RS 232 Output 8 Pitch Servo control lines These lines cause the stepping motor in the pitch servo to run in the Do NOT attempt to 9 appropriate direction at the desired velocity They are small signal lines and do not have any reverse servo direction by 10 substantial current carrying capability or require any special shielding Connect to pitch servo swapping wires 11 as shown on wiring diagram 12 Yaw Damper option 13 Ground Connection Provide 20 AWG to common grounding poin2. BLACK re ro 0 PITOT PORT AD O s UA Ly Po STATIC PORT L RS 232 14 ORANGE ARINC A 1 YELLOW ARINC B lg BLACK WHITE 1 BLUE 8 YELLOW 3 ORANGE GPS RECE VYER Note 1 Reversal of Pitch servo rotation is accomplished by installing or removing the jumper from pin 1 to pin 2 Note 2 Reversal of Roll servo rotation is accomplished by swapping wires at pin 4 amp 5 at the servo Pitch serva WHITE GREEN D 00 1 S OB ty O Hand held GPS must have a return signal ground CWS WIRE SHOULD BE SHEILDED TruTrak Flight Systems 7 November 2010 AFS Pilot Installation User Manual Rev A AFS Pilot Operation Operation of the AFS Pilot AP is very simple It has two modes 1 AP mode and 2 EFIS mode The operation of both modes is covered below AP mode operation Press the AP button to engage the system into AP mode When engaged this mode will hold the current GPS ground track and synchronize to the current vertical speed If the current vertical speed is less than 300 fpm the system will enter altitude hold mode When first engaged the cursor will be under the SEL numbers Rotating the knob at this time will change the selected track The number will change in 5 increments with each knob detent Pressing and holding the knob while turning it will give 1 increments A sample screenshot is shown below The scrolling bar in the middle of the display indicates a need for
3. including the autopilot connected to a single insufficient static port In other cases the static line itself is adequate but there are one or more devices connected to the same line one of which has a large static reservoir A simple remedy for this problem if it occurs is a tee fitting near the static port and a dedicated line to the autopilot only Obviously an insufficiently large orifice coupled with large static reservoirs can aggravate the problems associated with lag RFI EMI considerations The autopilot programmer is shielded and does not generate any appreciable level of electromagnetic interference Moreover the servo lines except for power and ground are low current and cannot contribute to RF interference The servo power and ground lines do have switching currents through them but so long as there are no parallel runs of servo power and ground lines with such things as poorly shielded antenna lines or strobe light power lines there is no need to shield the servo harnesses The autopilot itself has been internally protected from RF interference and has been tested under fairly extreme conditions such as close proximity to transmitting antennas However it is always good practice to insure that such antennas are properly shielded and not routed directly over or under sensitive panel mounted electronic equipment Most problems in this area are the result of improper RF shielding on transmitting antennas microphone cables and the
4. 24 or larger wire for all connections unless otherwise specified The standard solder pin contacts supplied in the connector kit are compatible with up to AWG 18 wire In cases where some installations have more than one component sharing a common circuit breaker sizing and wire gauge is based on length of wiring and current draw on units In these cases a larger gauge wire such as AWG 20 may be needed for power connections Do not attach any wires to the outside of the programmer or route high current wires within six 6 inch of the programmer Ensure that routing of the wiring is not exposed to sources of heat RF or EMI interference Check that there is ample space for the cabling and mating connectors Avoid sharp bends in cabling and routing near aircraft control cables Do not route the COM antenna coax near any autopilot components Pitot and Static Connections All multi servo TruTrak autopilots require connections to the pitot and static lines The preferred method of this connection would be tee fittings near the aircraft s altimeter The static line for the autopilot requires due care in its construction as excessive lag or insufficient static orifices can cause the autopilot to oscillate hunt in pitch Although there is compensation within the autopilot sufficient to handle moderate amounts of lag the importance of a good static port and line cannot be overstated In some cases problems can be caused by having a large number of devices
5. like The most sensitive input to the autopilot is the Control Wheel Switch input This line should not be routed in parallel with transmitting antennas or other sources of known RF interference If necessary it can be shielded with the shield connection to pin 13 of the autopilot connector TruTrak Flight Systems 2 AFS Pilot Installation User Manual November 2010 RevA AFS Pilot Series Ground Checkout Must be performed before first flight The check out procedure is to verify that the servos run and in the correct direction Once the track and altitude selections are returned to current both the pitch and roll servos should stop or move only very slowly If the direction of movement of the pitch servo is incorrect install or remove the jumper between pins 1 and 2 of the autopilot connector and repeat the setup to verify correct results up to this point The roll servo should also be responding at this time moving the controls in such a way as to turn the aircraft from the current heading If the selected heading is right of the current heading the control yoke or stick should move to roll the aircraft to the right Conversely a selected heading to the left of the current heading will move the controls in the opposite direction to attempt a roll towards the left If servo direction is not correct the wires going to pins 4 and 5 of the roll servo pins 20 and 21 on the main connector must be reversed to achieve the correct response If a servo
6. trim Scrolling up means trim up scrolling down means trim down Press and release the knob to move the cursor to the select vertical speed SVS mode Once there rotating the knob clockwise will increment the selected vertical speed by 100 fpm up with each knob detent Rotating the knob counter clockwise will increment the selected vertical speed by 100 fpm down with each knob detent After three seconds the cursor will move back to the SEL numbers It can be forced back to the SEL number by pressing and releasing the knob again To enter altitude hold mode move the cursor to SVS and rotate the knob the corresponding direction to reach a selected value of 0 To exit AP mode and disengage the autopilot press the AP button again or the CWS button Pressing the EFIS button will toggle the system to EFIS mode TruTrak Flight Systems 8 AFS Pilot Installation User Manual November 2010 Rev A EFIS mode operation Press the EFIS button to engage the system into EFIS mode Once in EFIS mode the system will take lateral and vertical steering commands from the AFS EFIS system that is interfaced to it The display will show EXT LS on the left side and VS on the right side To exit EFIS mode and disengaged the autopilot press the AP button or use the CWS switch if connected Pressing the EFIS button while in EFIS mode will toggle the system to AP mode Pressing and holding the CWS switch will put the AP into CWS mode In this mode the se
7. AFS Pilot Series Autopilots Installation User Manual Rev A TRUTRAK FLIGHT SYSTEMS 1500 S Old Missouri Road Springdale AR 72764 POSTAL SERVICE ADDRESS P O Box 189 Springdale AR 72765 0189 Ph 479 751 0250 Fax 479 751 3397 www trutrakap com INSTALLATION USER MANUAL For AFS Pilot Series Autopilots TABLE OF CONTENTS Mechanical Considerations u a a son eae ole ate SOUS ADS on th Saved a INS ND Na Sam aq NS aa ov SR Prtot Static Connections siano an a I dedgsbolagaesusedeahasedsghgeunsacegatadsgagsos Sesbesedaghys cus ceabstalazageossdeabenedegees RET PEM Considerations 2 5 33 n S Sh6 io liada Ground Check Outs uum m a ee mami Su tate First FUGA res agag awa atap kaa upa anu Q aqu n A AE Electrical PUE Q aun Ln a S a S lia WINS DAM su a a Sasa Aa SS hoa Ga a CIA Sua S a N SSS Caw au aS Block Diagram t 4 2 umaka hm a ei hia ee ae haqa uay a a eee ec ABS PilOt Operations S acess toss peste um ba hace Vids huata tue este E UGS i desea L Trutrak Watranty Descriptions nana bate tabs fa us idilio 12 RETURN MERCHANDISE POLICY AND PROCEDURFE a 13 Revision Date Description Page A 11 04 2010 Initial Release Mechanical Considerations The installation information in this section is extremely important and must be clearly understood by the installer Improper servo installation or failure to observe and diagnose installation proble
8. ISE POLICY AND PROCEDURE Under no circumstances should products be returned to TruTrak without first obtaining a Return of Merchandise Authorization number RMA from TruTrak An RMA may be obtained by contacting us at 866 878 8725 Products that do not have an RMA will not be processed Please include documentation stating the reason for the return and describing any symptoms failure modes suspected causes of damage diagnostics performed data collected etc Product s should be packaged in their original shipping containers In lieu of this they should be very carefully packaged in containers suitable to protect them during transit For your protection items should be insured for the full value Note that damage caused during shipping will not be repaired under warranty The outside of the box must be clearly marked with the RMA issued by TruTrak and the RMA must also be noted on the return documents Products will be returned to the customer at no charge via FedEx Ground or UPS Ground If customer requests expedited shipping 2 Day or Overnight they will be charged the shipping cost and must supply a credit card number INTERNATIONAL SHIPMENTS Trutrak sends all International shipments with an insurance value on all products Trutrak pays for shipping only The customer is responsible for any and all additional fees duties taxes associated with the shipment When sending products to Trutrak for repair or otherwise pleas
9. ch the cable leaves the capstan When the primary control is at the neutral point this means the total cable wrap around the capstan is 360 If the primary control travel is greater than 5 the cable wrap is 720 and the pin is adjacent to the output point when the primary control is at the neutral point The cable clamps when properly installed will not slip but it is desirable to NICO press or swedge a fitting on to the cable so as to provide added assurance that the cable will not become slack If the bridle cable is not sufficiently tight there will be lost motion in the autopilot drive This will result in hunting oscillation TruTrak Flight Systems 1 AFS Pilot Installation User Manual November 2010 Rev A PROGRAMMER INSTALLATION Mounting Considerations The AFS Pilot programmer unit is designed to mount in the aircraft instrument panel Maximum recommended viewing angle should be no more than 20 deg The maximum mounting angle the programmer can accommodate is 10 degrees longitudinal axis and 0 degrees lateral axis The primary unit location should minimize pilot head movement when transitioning between looking outside of the cockpit and viewing operating the programmer unit The location should be such that the programmer unit is not blocked by the glare shield on top or by the throttles control yoke etc on the bottom Use aircraft installation standards for mounting and support of the programmer Wiring Considerations Use AWG
10. does not move at all double check the torque voltage on pin six 6 of the servo If a servo jitters but does not actually rotate check the wiring on the four servo drive lines to that servo for continuity and correctness If the servo does not seem to have any torque check the relevant torque control line for continuity and correctness At this time check that each servo arm or capstan is properly operating the controls For servo installations using an arm check that as the controls go from limit to limit the arm of the servo remains in the operating range of the servo a maximum of 100 degrees total rotation and that when the controls are centered the connecting pushrod is approximately perpendicular to the arm of the servo For capstan systems insure that the cabling remains at proper tension and is properly secured as the servo moves the controls from stop to stop Insure that each servo remains secure in its mounting and does not flex its mounting bracket as it drives the control to its stops For installations using an arm insure that as the servo moves the control towards the end of control travel it does not cause the main control s torque tube or push pull tube to flex in any way that could cause control system lockup at the extremes of servo travel Insure that any lost motion in the linkages is eliminated or minimized in order to maximize the performance of the autopilot Lost motion dead zone will result in wandering or slow h
11. e be advised that the customer is responsible for all charges and fees associated with shipment For your protection items should be insured for the full value Trutrak states on all product returns WARRANTY REPAIR AT NO CHARGE TO CUSTOMER A COMMERCIAL INVOICE VALUE OF ___ GIVEN FOR INSURANCE PURPOSES ONLY Please keep in mind that your government or another entity in your country may impose a charge for custom and or brokerage fees duties and taxes on items received from the US These charges do not originate from our company nor do we benefit from them in any way You are responsible for payment of all custom and brokerage fees duties and taxes that may be imposed when these goods are imported into your country Send UPS FedEx DHL return shipments to Trutrak Flight Systems Inc 1500 South Old Missouri Road Springdale AR 72764 USA Attention Returns Dept RMA TruTrak Flight Systems 12 AFS Pilot Installation User Manual November 2010 Rev A TRUTRAK FLIGHT SYSTEMS 1500 S Old Missouri Road Springdale AR 72764 POSTAL SERVICE ADDRESS P O Box 189 Springdale AR 72765 0189 Ph 479 751 0250 Fax 479 751 3397 Toll free 866 TRUTRAK 866 878 8725 www trutrakap com
12. e this value at 12 unless advised by AFS or the factory MIN AS This is the minimum airspeed setting Set this sufficiently above clean stall speed to prevent aircraft stall but not high enough to interfere with maneuvering MAX AS This is the maximum airspeed setting Set this sufficiently below Vne but not enough to interfere with maneuvering TruTrak Flight Systems 3 AFS Pilot Installation User Manual November 2010 Rev A STATIC LAG This should be left at 0 unless advised by AFS or the factory MICROACTIVITY This should be left at 0 unless advised by AFS or the factory HALF STEP This should be left at N unless advised by AFS or the factory The first flight should be done after having completed all the setup and testing on the ground Insure that the servos have sufficient torque to properly fly the aircraft as they are installed The autopilot should be able to handle considerable turbulence It is best to test the autopilot in its basic mode first Engage it in the AP mode first before using it coupled to the AFS EFIS system This will insure you are able to tune the settings to correctly fly your aircraft before introducing another variable TruTrak Flight Systems 4 AFS Pilot Installation User Manual November 2010 RevA Electrical Pin out 123 4 5 6 7 8 9 10 11 12 13 0000000000000 000000000000 14 15 16 17 18 19 20 21 22 23 24 25 viewed from rear of unit Rear 25 Pin Connector P101
13. ms prior to flight can result in extremely serious consequences including loss of ability to control the aircraft If there are any questions on the part of the installer it is mandatory to resolve these questions prior to flight of the aircraft Most modern experimental aircraft use push pull tubes to drive the primary controls These tubes generally have a total travel of 3 or less therefore it is best to connect the autopilot servo to the primary control by the same method This connection consists of an arm on the servo connected by a push pull rod to the primary control Rod end bearings are required on each end of the push pull rod The servo arm must not rotate even near to the point called OVER CENTER the point at which the primary aircraft control would lock up Some aircrafts mechanical primary control installations will not allow this to occur and do not need the servo stops This is a condition that would result from the servo being back driven when the pilot operates the controls or from the servo itself driving the controls to a stop To protect against this mechanical stops are supplied with the servos These stops are drilled so that they can be mounted at different angles as required 18 intervals the servo can handle With the push rod connected to the outermost hole 1 12 the travel on the primary cannot exceed 2 1 2 the intermediate hole 2 1 16 and the inner hole 1 5 8 It is important to note that a
14. ruTrak Flight Systems 5 AFS Pilot Installation User Manual November 2010 Rev A AFS Pilot Wiring Diagram NOTE 13 USE 420 AWG HIRE FOR POWER amp GROUND TO SERVOS amp WIRE TO AUTOPILOT MASTER ALSO SINGLE POINT GROUND ALL OTHER WIRING 20 TO 24 AWG AUTOPILOT MUST HAVE PRIMARY SERIAL INPUT NOTE 2 ROLL SERVO ONLY REVERSAL OF THE SERVO DIRECTION CAN BE ACCOMPLISHED IF NECESSARY BY SWAPPING WIRES AT PIN 4 amp 5 OF THE SERVO CONNECTOR PITCH SERVO 9 PIN FEMALE D SUBM INI TURE NOTE 3 PITCH SERVO ONLY REVERSAL OF SERVO DIRECTION CAN BE ACCOMPLISHED AS NECESSARY BY INSTALLING OR REMOVING A JUMPER BETWEEN PINS 1 amp 2 OF THE 25 PIN CONNECTOR 12 28 VOLTS 5 AMP CB AIRCRAFT POWER Po AUTO PILOT MASTER AIRCRAFT GROUND RS 232 QUTPUT lt o o YAW DAMPER ENGAGE FR 14 15 16 17 ial i9l 20 21 22 23 24 25 GPS NMEA INPUT PRIMARY SERIAL INPUT TAN H GPS ARINC B CAN L GPS ARINC A Z ZN NOTE 2 1 2 3 tt El x S J e a T dT g AFS PILOT EXTERNAL WIRING DIAGRAM ROLL SERVO D SUBMINITURE TruTrak Flight Systems 6 AFS Pilot Installation User Manual Rev A November 2010 AFS Pilot Block Diagram AP Master SWT To Aircraft Buss O 3 Amp CB Roll Serva ee YELL Ob LOOP
15. rvos temporarily disengage and you can steer the autopilot to a new course and new altitude or vertical speed When the button is released the autopilot will hold the new course and vertical speed or enter altitude hold The AFS Pilot can follow a programmed flight plan from a GPS independent of the EFIS system by pushing the EFIS button The screen will display EXT LS to indicate that it is following an external lateral steering signal TruTrak Flight Systems 9 AFS Pilot Installation User Manual November 2010 Rev A TruTrak Flight Systems 10 AFS Pilot Installation User Manual November 2010 Rev A Warranty On TruTrak Flight Systems Products We at TruTrak Flight Systems know how important it is to feel as though the customer is purchasing a product that the manufacturer is going to stand behind For this reason we want offer more than the basic one year warranty that is standard to this industry The warranty on all TruTrak products will be three years from the date of purchase Abuse and misuse of a product are not covered under this warranty Modification to a product may void the warranty as well as carry a penalty when upgrading to another product This three year warranty will be for all products except the Pictorial Turn amp Bank which will continue to have a warranty of one year from the date of purchase TruTrak Flight Systems 11 AFS Pilot Installation User Manual November 2010 Rev A TS TRUTRAK FLIGHT SYSTEMS RETURN MERCHAND
16. t 14 ARINC A Digital differential signals from Garmin Sierra or other panel mount receiver 15 ARINC B which provide directional steering commands GPSS GPSV to autopilot 16 Roll Servo Torque Control A signal from the autopilot to the roll aileron servo which sets the amount of torque to be delivered by the servo 17 Primary Serial Input Baud rate selectable 1200 2400 4800 or 9600 baud Automatically decodes NMEA 0183 Garmin Aviation Format or Apollo UPSAT Moving Map or GPSS format Provides directional reference to the autopilot 18 Auxiliary RS 232 Input Presently unused intended for future expansion 19 No connection Roll aileron Servo control lines These lines cause the stepping motor in the roll servo to run Reverse servo direction if in the appropriate direction at the desired velocity They are small signal lines and do not have necessary by swapping 20 any substantial current carrying capability or require any special shielding Connect to roll wires on pins 20 and 21 21 servo as shown on wiring diagram See note 2 on wiring 22 diagram 23 Wiring to roll servo J201 Direction of servo arm capstan rotation as viewed from face of the servo body J101 Pin 20 Pin 21 for RIGHT aileron Standard J201 4 J201 5 Servo CCW counter clockwise gt RIGHT Reversed J201 5 J201 4 Servo CW clockwise gt RIGHT 24 No Connection Reserved for future expansion 25 No Connection Reserved for future expansion T
17. t the neutral point of the control the SERVO ARM must be PERPENDICULAR to the push rod and that the stop must be mounted so as to limit travel as near as possible to equal amounts in both In addition to the proper use of the stop it is important to know the amount of travel on the primary control that A directions In certain factory designed installations there may be well proven exceptions There will be installations in which space does not permit the use of the stop When this is done the aircraft s primary control stops must be positive and care must be taken to be sure that at the neutral point the servo arm is perpendicular to the push rod and that the travel limits of the servo arm are not exceeded There are installations in which the travel of the push pull tube exceeds the allowable 2 1 2 For such installations the drive can be applied to a bell crank at a radius point that moves the desired 2 1 2 of maximum allowed travel in the outermost hole of the arm When there is no way to have a drive point of less than 2 Y2 or when the primary control is cable driven it is necessary to use the capstan cable servo drive When this is done the servo should be mounted so that the 1 16 diameter cable which wraps around the capstan when extended parallel to the primary cable is approximately 3 16 from the primary cable If the primary control travel does not exceed 5 the cable locking pin will be 180 away from the point at whi
18. unting behavior in flight AFS Pilot First Flight The factory default settings for the autopilot will not work for every aircraft type but in most cases are good points from which to start A brief description of each setting is given below beginning with the lateral setup menu To access the lateral setup menu press and hold the AP button LAT ACTIVITY Increase this number to cure a slow wandering across track decrease it to cure an overactive stick yoke LAT TORQUE Leave this value set at 12 unless advised by AFS or the factory BAUD RATE This setting is determined by your GPS default is 9600 BANK ANGLE This setting determines the approximate bank angle in AP mode only It has no effect in EFIS mode GPSS GAIN This setting should be left at 16 unless advised by AFS or the factory MICROACTIVITY This setting should be left at 0 unless advised by AFS or the factory YAW DAMPER This setting should be left at N unless a Trutrak yaw damper system is installed That is the last setting in the lateral setup menu Now move on to the vertical setup menu To access the vertical setup menu press and hold the EFIS button PITCH AXIS Setting this to N will result in the pitch servo being deactivated When the power is cycled to the system it will default back to Y with the pitch servo active VRT ACTIVITY Increase this number to cure a slow porpoise decrease it to cure a bouncing feeling in altitude hold VRT TORQUE Leav
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