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1. 2 2 8 Language Setting Choose different languages for different users 1 Rotate the Knob to select LANGUAGE SETTING in the installation menu Press the Knob to show the following window INSTALLATION MENU SELECT REMOTE UNIT LANGUAGE SETTING ENGLISH Cancel ESC ok ENT LANGUAGE SETTING 2 Rotate the Knob to select desire language and press the Knob to save change or press ESC to exit without save the change 2 2 9 Output Setting OUTPUT SETTING OUTPUT SETTING 2 HDM 3 HDG Cancel ESC ok ENT Output data available from KAP 866 includes the following three types HDT True heading HDM Magnetic heading HDG Magnetic heading amp magnetic variation value Note the default magnetic value is 0 since there are no enough data to calculate the magnetic variation In calculation of magnetic value it requires position data LON LAT and date those data are not available in KAP 866 Note Since there are no available data in KAP 866 for calculation of magnetic vari ation therefore HDT outputs magnetic bearing instead of ture heading data The magnetic variation data in HDM would be 0 2 2 10 Factory Default Setting For any reason need to reset all settings to factory default setting you can do as following instruction 1 Rotate the knob to select FACTORY DEFAULT SETTING in installation menu Press the Knob to show there following window INSTALLATION MENU FACTORY DEFAULT
2. Engaging Navigation Mode Press NAV change the steering mode to Navigation mode and NAV display on the Mode field to indicate the steering is directed by the connected GPS Navigator The vessel will begin turnin from its current course to the course requested by the GPS Navigation If no GPS data is being received by the KAP 866 the autopilot will lock onto the course of the vessel at the time that Navigation Mode was engaged and the No GPS Data alarm shall sound Setting up your GPS Navigator Because there are a great variety of GPS Navigator that will work with this autopilot the following is a guide only For more information Please study your GPS Navigator manual The GPS Navigator must be set up to output NMEAO0183 data on a pair of wires which are connected to the GPS IN terminal connections on KAP 866 The data generated must include at least one of the followings e The APA sentence e The APB sentence e The BOD and XTE Sentences If only the XTE data sentence is available the pilot can steer in a Restricted manner See later in this section The GPS unit must then be commanded to go to a waypoint or to follow a line joining two or more waypoints called a route This unit will then send information to the autopilot from which can be calcu lated the course to steer IF several waypoints are linked together into a single route and the GPS unit is set to auto sequenence between them and an arrival z
3. HEADING ALIGNMENT SETTING l LANGUAGE SETTING LANGUAGE SETTING 2 2 3 Select Magnetic Sensor Unit There are 2 kinds of Magnetic Heading Sensor units are available from Onwa Fluxgate compass Top Sensor Note Choice of Magnetic Sensor Unit 1 Fluxgate Sensor KFG25 and KFG28 FLUXGATE SENSOR 2 Compass Top Sensor KCS20 COMPASS TOP SENSOR INSTALLATION MENU SELECT MAGNETIC SENSOR UNI 1 FLUXGATE SENSOR 2 COMPASS TOP SENSOR Cancel ES C ok ENT HE LANGUAGE SETTING 2 2 4 Trim Setting Sometimes for some reasons the installation of Rudder Feedback Unit is not 100 aligned with the position of the Rudder We could use the Trim Setting to compensate the installation error Note It is not advised to use this function to compensate the error if the angle different is excess 5 degrees between actual rudder angle and display angle from rudder feedback unit Re installation should be carried out if the said angle error is excessed 5 degrees INSTALLATION MENU TRIM SETTING 00 Cancel ESC ok ENT LANGUAGE SETTING 2 2 5 Auto Heading Adjust The compass 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 t
4. e Remove dust and dirt from the display unit and fluxgate sensor unit with a dry soft cloth For the LCD wipe it carefully to prevent scratching using tissue paper and an LCD cleaner To remove stubborn dirt use an LCD cleaner wiping slowly with tissue paper so as to dissolve the dirt Change paper frequently so the dirt will not scratch the LCD Do not use chemical cleaners for cleaning they can remove paint and markings Note do not use contain chemical cleaners clean it might help to eliminate paint and equipment will be marked 5 2 Troubleshooting This section provides basic troubleshooting procedures which the user may follow to restore normal operation Troubleshooting Power cable on the Firmly connect the power display unit cable Cannot turn on Power supply failure Check the power supply 027 Replace fuse with correct Blown fuse rating Have a qualified technician to check if fuse blown again after replacement Heading indication changes randomly when ship is at Sensor trouble or Run the diagnostic test anchor or does Cable contact is bad to determine cause not change when ship moves Rudder not Low voltage output Check voltage supply to functioning from KAP 866 or KAP 866 steering system proble Check the steering system No rudder angle RFU problem or RFU 1 Check RFU indication cable contact is bad 2 Check RFU cable Check RFU and rudder connection If large heading error occurs or
5. R estore to factory default setting Cancel ESC ok E NT 2 Press the Knob to clear all saved settings or press ESC to exist without clear the saved setting Note When you select to load factory default setting all saved settings would be cleared This action can not reversible 2 2 11 Select Type of Steering System Some vessel the steering system is either common positive solenoid or common negative solenoid or reversing motor KAP 866 can be set to work with above Systems 1 Rotate the Knob to select SELECT TYPE OF STEERING SYSTEM in the installation menu Press the Knob to show the following selection INSTALLATION MENU SELECT TYPE OF STEERING SYSTEM SEN1 COMMON POSITIVE SOLENOID 1 2 COMMON NEGATIVE SOLENOID 3 REVERSING MOTOR Cancel ES C ok ENT 2 Rotate the Knob to select the correct system and press the Knob to save setting or press ESC to exit without save the change 3 AUTOPILOT INSTALLATION 3 1 Installation of Main Unit 3 1 1 Position The KAP 866 main panel should be mounted in an accessible position Protec ted from rain or salt water 3 1 2 Wiring Cablings have to be run from KAP 866 to the rudder feedback unit compass unit compass unit and steering drive system Wiring should be kept as far away as possible from radio aerials and aerial cables to prevent interference to the radio and to prevent transmitted signals from the radio influencing to the autopilot The pow
6. The bulkhead installation can save the space The bulkhead cannot contain the steel with magnetic interference material Deck ea Bracket Top Mount Fluxgate Sensor Side Mount Bulkhead gt Fluxgate Sensor Examples of bulkhead Mount 3 3 3 Installation an outdoor magnetic sensor unit KFG 28 Outdoor installation Keep the length of the cable in mind when selecting a mounting location It should be far away from their minimum 1 meters to prevent the influence for iron and steel or other magnetic materials use not magnetic screws for fixed the fluxgate sensor unit Select the vertical way of positions for installation Please installed the magnetic sensor unit on the top of wheelhouse Don t install it in a room so that the magnetic distortion can be minimized a Cable to display unit Fluxgate Sensor Fixed screw Threaded tubes At least one meter length Mast Wheelhouse _ UUUUL 3 4 Installation of solenoid 3 4 1 Connect common positive solenoids as follow If the rudder goes to reverse direction against KAP 866 command then you need to reverse the connection of Motor 1 amp Motor 2 Motor 1 Motor 2 St b solenoid Clutch 3 Negative lead of power supply 3 4 2 Connect common negative solenoids as follow If the rudder goes to reverse direction against KAP 866 command then you need to reverse the connection o
7. SETTINGS cis cis cts cee coe nmn o tnn no ron em n n ose nee ven sen s34 ose 636 T 21 Function Menm ater sse 4x x42 ots enn cee van cee s48 545 366 descends cos wen ree coe aeos ens on MM ase Co le oe ec eee 6 Om Bhi ee ro es a 2 1 3 Stopwatch Timer Alarms HMM tr me se se TT ae OF Course Alarma Secun qup Sut miS xU PER ee E es ae 22 Installation Menu seek 006 ses see nr nnn des nhe see s46 ver oso 7 DOT Select amoto DL isseieuste 30812008 nsa HUI tenets anta Feds tee dona de acd 2 5 5 Select Rudder Feedback Unibsssss sra wae ve ees ves vas eos 2 2 3 Select Magnetic Sensor Units HH eeesee ceesre eee 4 2 2 4 Trim Settings m mmm nme 4 2 2 5 Auto Heading Adjust mmm HH 5 2 2 6 Manual Heading Settings mmm mH cee cee ene eee eee eee 6 2 2 7 Heading Alignment Settings sm HIT 2 2 8 Language Settings mmm 2 2 9 Output Settings Henne 2 2 10 Factory Default Settings cee cee cee cee th cee tee cee eH 2 2 11 Select Type of Steering System sem m cee cee tee tee nhe eee eee eee 9 CONTENTS 20 20 20 20 20 20 21 21 22 29 T O 24 26 2 25 8 20 30 3 32 3 3 34 00035 00035 5 5 5 5 36 6838 4 AUTOPILOT INSTALLATION t t tt t 064006 T Tallon ol Nimm re rer gii Postoy SECE
8. heading indication is frequently interrupted contact your dealer for advice 6 TECHNICAL PARAMETERS 6 1 General 6 1 1 Heading Reference Fluxgate Magnetic Compass NMEA 6 1 2 Heading Sensor KFG 25 standard KFG 28 amp KCS 20 option 6 1 3 Heading Resolution 1 6 1 4 Course Detection 0 1 6 2 Output Input IEC61162 6 2 1 Input Dual NMEA 0183 inputs Support APA APB BOD amp XTE HDG HDT HGM Baud Rate 4800 n 8 1 6 2 2 Output One 0183 output support HDG HGT HGM Baud Rate 4800 n 8 1 6 3 Environmental Conditions 6 3 1 Ambient Temperature 15 C 70 C 6 3 2 Waterproofing Display Unit IPX5 Fluxgate Sensor Unit IPX5 for KFG25 IPX7 for KFG25 Rudder Feedback IPX7 6 4 Display 6 4 1 Sunlight viewable high contrast LCD 6 4 2 LCD size 95 W X 63 H mm 240X160 dots 6 5 Electrical parameters 6 5 1 Operating Voltage 10 to 30VDC 6 5 2 Power Consumption Standby mode 0 4 Amps Auto mode 1 0 Amps Peak for control unit only 6 5 3 Drive Output 20 Amps max 7 INTERCONNECTION DIAGRAM LE EH POWER SUPPLY MAGNETIC SENSOR o9 n EXT ALARM EXT ANGLE IND NMEA0183 GPS REMOTE WHEEL E SOLENOID OR REVERSING MOTOR 1 MOT 2 MOT 3 CLU 4 CLU MAGNETIC SENSOR 1 Green POWER 2 Red 1 DC input 3 Yellow 2 DC input 4 White 5 Blue 6 Shield EXT ALAR
9. of awrong fuse can damage the Use the properfuse equipment or cause fire Use of awrong fuse candamage the equipment or causefire Be sure thepower supply is compatible with the equipment Incorrect power supply may cause the equipment to overheat NOTICE The useable temperaturerange Observe the following compass safe 15 C to 55C for the display unit distances to prevent interference to a magnetic compass Use of theequipment out ofthose ranges may damagethe equipment es Steering Compass Compass Display unit Processor KFG 25 1 2 m 1 2 m WARNING Automatic pilots are designed to be a navigational aid As an automatic steering aid an autopilot can alleviate the boredom of hand steering This allows the operator of the vessel time to attend to other duties keep a more accurate check of navigation duties or just relax and enjoy the trip HOWEVER THE AUTOPILOT SHOULD NOT BE LEFT SOLELY IN CHARGE OF THE VESSEL AND AN ADEQUATE WATCH SHOULD BE MAINTAINED AT ALL TIMES IT IS NOT RECOMMENDED THAT THE AUTOPILOT BE USED WHILE NAVIGATING IN RESTRICTED WATERWAYS AS WATER CURRENTS WIND CHANGES OR RADIO TRANSMITTER INTERFERENCE MAY AFFCT VESSEL COURSE SUFFICIENTLY TO ENDANGER YOUR OWN OR OTHER VESSELS FOREWORD Thanks you for purchasing the ONWA KAP 866 Autopilot The KAP 866 Autopilot controls the vessel steering through mechanical drive reversing pump set solenoid valves or relays The compass must be ins
10. select other modes ST BY or F UP than AUTO or NAV modes or change the timer to 000 If the STOPWATCH TIMER ALARM 1s triggered and the user without press ESC to cancel the alarm within one minute the alarm sound will change form short beep to continuous long beep and the external alarm if installed will be triggered 2 1 4 Off Course Alarm An alarm will sound if the vessel has deviated from its desired course by more than a set number of degrees This can be caused by a number of steering faults any of which require attention by the crew The angle at which this alarm sounds may be set to any value between 1 and 180 degrees To set the off course alarm angle In any mode press MENU to display Function menu Rotate the Knob to move cursor to Off Course Alarm and press the Knob to confirm Rotate the Konb to change setting from 0 180 degrees and press the Knob to save setting or press ESC to exit without save the setting When the allowable angle is exceeded the off course alarm will sound and a flashing OFF COURSE will show on display When the vessel is brought on to its correct course again the alarm will cease Note that the alarm will sound if a large course change is entered This alarm will cease as soon as the vessel completes its course change The alarm may also sound when changing from one section of a GPS route to another and will cancel itself when the course change is completed The default va
11. the above steps until the correction is successful 2 2 6 Manual Heading Setting Manual Compensation is a supplement to the type of single orientation parabola to adjacent 10 degrees This method could be done by qualified personnel 1 In the Installation menu select MANUAL HEADING SETTING and press the Knob the following window appears MANUAL HEADING ADJUST 120 240 00 30 00 150 270 00 60 00 180 300 00 90 00 210 330 00 Cancel ESC OK ENT 2 Rotate the Knob to choose which bearing you want to correct and press the Knob to confirm Rotate the Knob to apply compensation and press the Knob to save the change or press ESC to exit without save Note Anyway ship s magnetic compass and heading on KAP 866 shows each azimuth are unlikely to maintain consistent 2 2 7 Heading Alignment Setting Adjustment of heading might be needed during installation Usually a fixed error in all direction would exist It is due to the mechanical error when fixing 1 Rotate the Knob to select HEADING ALIGNMENT SETTING in the inst allation menu Press the Knob to show the following window INSTALLATION MENU SELECT REMOTE UNIT Heading alignment setting 134 00 134 Cancel ESC ok ENT HEADING ALLGNMENI SEIILNG LANGUAGE SETTING 2 Rotate the Knob to change the heading alignment setting and press the Knob to save the change or press ESC to exist the window with out save the change
12. units are very easy just plug and play Connect the remote units to the KAP 866 remote connector with the supplied cable 3 9 Installation of external rudder indicator Onwa rudder indicator KRI 80 is supplied an option Connect KRI 80 to KAP 866 as follow KAP 866 Autopilot RUDDER INDICATOR MODEL KRI 80 S NO 090700001 5K control resistor for dimmer control Center and Range Calibration is needed on the KRI 80 after installation Place the rudder on midship position adjust Center VR on KRI 80 to get 0 degree on the meter Place the rudder to 30 degree on either port or starboard adjust Range VR on KRI 80 to get 30 degree on the meter 4 Commissioning Checks Connection Tests Voltage to be connected is the required DC voltage 12 or 24V Important note The supply voltage must match the operating voltage of solen oid or reversing motor Ensure polarity of the voltage supply is correct All electrical connections are correct Tie up or cut the unused wires Turn steering wheel fully clockwise and visually check that moving and mechanical parts do not foul visually check that RFU has moved in the correct direction as indicated on the RFU label Note RFU Rudder Feedback Unit Dockside Tests e Turn steering by hand to centre midships position Turn on power sup
13. Autopilot Ver 20120101001 ONWA TURNING OFF IN 3 SEC NOTE If the device is a long time when not in use Better to turn off the main switch of the power supply unit 1 3 Display backlight and contrast adjustment 1 Press the POWER key Dialog box for adjustment of Panel brilliance and display contrast 40 50 60 Heading BRILL 1 8 ea mo CONTRAST 0 63 42 EXIT ESC 2 Turn the Knob to select BRILL box and press the Knob to confirm then turning the Knob to change the backlight brilliance and press the Knob again to confirm the setting 3 Turn the Knob to select CONTRAST box and press the Knob to confirm then turning the Knob to change the display contrast and press the Knob again to confirm the setting 4 Press ESC to exit 80 E 100 110 120 1 4 Standby Mode Heading When switching on the unit it stays on o 80 Standby Mode and Man display on the Weather 3 Heading Mode field to indicate the steering oper ET EM 0 8 0 ate manually Glo ode Mai 3427794 53 3 Mode field Command field Rudder Angle Field In any steering mode press ST BY can return to manual steering mode 4 1 5 Auto Mode ie Press Auto change steering mode to Auto and A 707 on the MOGE field to indicate NR the steering operate automatic to the s
14. DE PO ESSER E VAR OAS SEER Oe 3 1 3 Magnetic 6 7 3 1 4 Power supply considerations seem m nnn 25 Tasullatiomn ofEudder Eeedbackuieredes eenessrausdisdud buo lu PETER Lat one 9002499468 2 q Dosiiiodsitevewerdazas dtevssatasdderabe nbbcssdbduvuo dienes 3 3 Installation of Compasses seem mn n enn eene nee es 3 3 1 Installing a Compass Top Sensor KC S 20 e serens e4 644665 cee oon one ne 3 3 2 Installing an indoor magnetic sensor unit KFG 25 t crete cee nn 3 3 3 Installation an outdoor magnetic sensor unit KFG 28 3 Installation ol solenoizssseenenwssusdd dis cato basceeiu bug 3 5 Installation of reversing motor pumps ttt 99 ece tt s t tt mn nn 3 6 NMEA Connection hne hehe nh ehe heh een ho 0008 0 006 00010 0806 0106 00 37 psremol Alarm Installattomesdiedses ntes ane O ODE OE eaa QU ade e cones 2s Tastallation 0f Remote UR E AEDST quic ea nan hor dad Vv sad ENE UE Eee CMCC LOR eC COORG pup delati QU 4 Commissioning Checks Connection Tes S cee 5 MAINTENANCE TROUBLESHOOTING cee eee eee eee es 5 1 Preventive maintenance ese se nen nnn he hen sos wes heh see oss tee eso cee 00000 086 006 hon on 5 2 Troubleshooting cee cee nnn 6 TECHNICAL PARAM
15. ETERS 6 1 General 6 2 Output Input IEC61162 e eseese ereere ee cee cee tee cee tee tee cee tee 6 3 Environmental Conditions rr hne n4 hne cee cen tae nee nee 6006 08 6 4 Displaycrr cesses cts nen cee cee cee nnn nnn cee es 6 5 Electrical parameters ce cee cee eee cee cee cee the cee nnn cee ee 5 tec tases sas INTERCONNECTION DIAGRAM 7 8 DISPLAY UNIT SIZE SAFETY INSTRUCTIONS Safety Instructions for the Operator Safety Instructions for the Installer WARNING WARNING Do not open the equipment Do not openthe cover unlesstotally familiar with electrical circuits and Only qualified personnelshould work service manual inside the equipment Improper handling can result in Do not disassemble or modify the electrical shock equipment Turn off the power at the switchboard Fire electrical shock or serious injury before beginning the installation can result Fire or electrical shock can resultif the Immediately turn offthe power at power is lefton the switchboard ifthe equipment is Be sure thatthe power supplyis emitting smoke orfire compatible with the voltage rating Continued use ofthe equipment can ot tae equipment cause fire orelectrical shock Contact Connection of anincorrect power a ONWA agent for service supply can causefire or equipment damage Use the properfuse Use
16. M amp ANGLEIND RUDDER 1 Alarm 2 Alarm 2 Sig 3 3 GND 4 Rudder Indicator 5 GND NMEA0183 I O REMOTE 1 Input 1 1 Adjust 2 Input 1 2 Controll 3 Output 3 Adjust 4 GND 4 Control2 5 Input 2 5 5V 6 Input 2 6 GND 7 NC 7 8 GND 8 DISPLAY UNIT SIZE A EEEE EE _ 0 _ 39 50 107 1085 58 5 130 Os EX d F amp 40 1 TRUE 6 50
17. ONWA KAP 866 KAP 866 OPERATOR S MANUAL Autopilot CONTENTS WARNING ae cee cee cee cee cee cee cee cee FEATURES cee cae cae vee cee cee nee cee 4 OPER ATION cee cee S one cee MINIMI 1 1 CONtrol Sore tee wee cee cee cee vee one woe wae 0 00 wee 9 0 6 5 1 2 Turning the power on off coo oco ooo ooo 066 060 000 000 0606 000 000 000 066 000 000 000 000 000 0666 666 66 1 3 Display backlight and contrast adjustments sess cco oco ooo ooo 6606 6606 0606 06606 6606 0666 000 66 1 4 Standby Mode coo soo ooo ooo cee 9600 960 900 060 060 060 060 0600 0600 000 000 000 0666 06606 06606 06606 06606 6606 6606 6606 66 1 5 Auto Modders 222 222 288 288 88 888 888 eee cee cee cee cee cee wee cee wee ee cee wee one one vee vee cee see one oe 1 5 1 Weather Controless 9 IH cee cee coe cee cee Ih cee cee wee ee coe cee ve 1 5 7 Rudder Control Rudder Ratio TTC 1 5 3 Counter Rudder Control III 1 6 Follow Up Mode cco coo ooo 0660 060 0606 06060 06600 060 06060 000 090 066060 0600 066 6660 6606 0666 000 066 666 6606 66 1 7 Navigation Mode 222 222 222 288 888 288 288 vee oe 4 0 DAAAA KRW Dw 2 MENU
18. correct b No undue mechanical strain is placed on the rudder feedback or linkage NOTE THE AUTOPILOT WILL NOT FUNCTION CORRECTLY IF A RUDDER FEEDBACK NOT FITTED OR IF THE FEEDBACK 5 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 3 3 Installation of Compass There are two types of compass suitable for this autopilot a magnetic sensor unit fluxgate which is a complete compass and the compass top sensor CTS which is used together with a standard magnetic ships compass 3 3 1 Installing a Compass Top Sensor KCS 20 The sensor unit placed on the glass plate of the ships compass in the exact centre of the compas card and secured with an adhesive such as double sided tape or silicon sealant Before fixing the sensor in place align it carefully so that the KAP 866 compass displays the same bearing as the ships compass The compass top sensor is preferred for steel hull vessels provided a suitably compensated compass is fitted to the vessel Bow Compass sensor Keel line Compass Bow Compass sensor Parallel travel 3 3 2 Installing an indoor magnetic sensor unit KFG 25 The compass unit should be treated ca
19. d to be changed Unless the loading of your vessel is changed If you adjust the counter rudder seting to A the counter rudder functioning automatically apply depends on the rate of vessel turning to the set course 1 6 Follow Up Mode Press FU to change the steering mode to Follow Up and FU display on the Mode field to indicate the rudder steer follows the set command angle on the Command field Set rudder angle can change the course of the 800 Heading autopilot a Rotating the knob will change the rudder angle command by one degree for each click Rudder 10 Counter Rudder will steer and stop on the set angle and Set Rudder direction Rotate the Knob to clockwise direction to drive the rudder to Starboard side while rotate the Knob to Counter Clockwise direction to drive the rudder to Port side b Pressing the W or arrow keys will cause a one rudder angle change in that direction 1 7 Navigation Mode For use when KAP 866 is interfaced to a GPS Navigator with NMEAO0183 data output In Navigation mode this allows the autopilot to Heading be directed by the GPS Navigator enabling lt automatic heading changes and eliminating the Weather 16 effects of wind and tide The number displays on the Command field Mode Nav indicates the course to steer which will be the bearing between the origin ad destination Waypoints plus a factor to correct for the Current crosstrack error XTE
20. e installed with the shaft uppermost mounted and linked in sucha way that the four pivot points tiller post feedback shaft and the adjustable linkage points form the four corners of a parallelogram 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 rudder feedback unit may be mounted ups ide down in which case the black and red connections to the KAP 866 ter minal should be reversed Optional Connection Arm Rudder feedback unit l m eee ee ee ee Rudder 3 2 2 Wiring Connect the cable of rudder feedback unit to the 3 pins socket on the rear panel of KAP 866 To check the wirng of the rudder feedback unit by steer the rudder to either side Port or Starboard see whether the rudder angle indication on KAP 866 goes to corresponding direction If the rudder angle indication on KAP 866 goes to reverse direction against the applied rudder then you need to reverse the wiring of RED and BLACK m re p I 1 Terminal5V t 5 volts Red Terminal Rud Signal Yellow Terminal GND GND Black After installation of the feedback unit is complete and the linkage is fitted have the steering of the vessel turned lock to lock and ensure a The direction port or starboard indicated on the top of the RFU 1s
21. er source for the autopilot should be fused separately from other equipment Maintain conventional colour coding and if necessary mark the cables for ease of identification Connection As per diagram labelled Connection Diagram for KAP 866 3 1 3 Magnetic Effect As a minimum amount of steel is used in the control unit there is negligible effect on a steering compass Some radio interference may be caused and the routing of cables should be considered when wiring the vessel 3 1 4 Power supply consideration KAP 866 can be operated with 12VDC or 24VDC To consider to use 12VDC or 24VDC you have to find out the operating voltage of steering drive system onboard first Usually the steering drive system is solenoid drive or reversing motor drive If the steering drive system onboard is operated on 12VDC the you have to connect 12VDC power suppl to KAP 866 If the steering drive system onboard is operated on 24VDC then you have to connect 24VDC power supply to KAP 866 I2VDC or 24VDC POWER SUPPLY 3 2 Installation of Rudder Feedback 3 2 1 Position Install rudder feedback as shown in the diagram labelled Rudder Feedback Unit Installation The unit should be adjacent to the tiller and must copy the angular movement of the tiller The markings on the rudder feedback unit indicates the required movement of the tiller for course correction It should b
22. et course Rudder 10 0 6 0 Counter The autopilot will lock on to the current a Rotating the Knob to change the course to steer by one heading Change course as follows degree for each click b Pressing the W or arrow keys will also cause a one degree course change for each press to corresponding direction Controls press the CTRL to select corresponding controls Weather Rudder and Counter Rudder Turning the Knob to change the setting ofthe controls then press the Knob to confirm the setting or press ESC to exit 1 5 1 Weather Control This setting 1s used for adjusting the autopilot s reponse on varies sea conditions The weather value sets the desired accuracy of the vesse steering A high weather setting will cause the vessel to steer very accurately but may cause excessive use of the steering In good weather set this control to a high value but ensure that the drive arrows display on ship s heading field would not flickering continuously This will give the straightest possible course In poor weather reduce this setting to prevent over working the steering 1 5 2 Rudder Control Rudder Ratio This setting is used to determine the amount of rudder that the vessel requires for steering actually the amount of rudder angle applied for a given angle off course The centre position is usually suitable for most vessels but also should depends on the vessel s steering be sensitive or slow ad
23. f Motor 1 amp Motor 2 s St b solenoid Motor 2 Clutch 3 Positive lead of power supply 3 5 Installation of reversing motor pump Connect reversing motor pump as follow If the rudder goes to reverse direction agains t KAP 866 command you need to reverse the connection of Motor 1 amp Motor 2 Reversing Motor Pump Motor 2 3 6 NMEA Connection KAP 866 can accept extermal heading information in format 3 4800 8n1 to replace standard fluxgate magnetic sensor KAP 866 can accept either one of the followings 183 sentence for heading source 1 HDG 2 HDT 3 HDM When KAP 866 find either one of above NMEAO183 sentence appear on the data in terminal then KAP 866 can priority choose the NMEAO0183 sentence as heading source KAP 866 can also accept GPS information in format of NMEAO183 4800 8n1 as course setting command When there is a route or waypoint navigation is engaged in the GPS device KAP 866 will follow the command from the GPS device to drive the vessel to the waypoint or route which is set in the GPS device KAP 866 can accept either one of the following NMEAO0183 sentence for navigation 1 APA 2 APB 3 BOD amp XTE Data In For GPS navigation or heading information Co
24. he KAP 866 display as constant offset e g The compass reads 3 degrees high on all bearings simply rotate the Fluxgate Sensor case to align bearings with the ships compass It is not necessary to re calibrate the compass as desc ribed below If the KAP 866 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 In the menu select AUTO HEADING ADJUST and press knob The following window appears INSTALLATION MENU AUTO HEADING ADJUST Auto heading adjusting Pleases keep constant speed less than 2 minutes for each turn Cancel ES C ok ENT LANGUAGE SETTING Press the knob to start auto heading adjustment Auto heading adjusting message will appear on the lower part of the display and heading update per second to show the status of adjustment Y 40 50 60 70 80 E 100 110 120 080 Weather SetCourse Em Auto heading adjusting Steer the vessel in clockwise direction with constant speed less than 2 minutes per each circle until the following correction success message appear v 40 50 60 70 80 E 100 110 120 v 40 50 60 70 80 E 100 110 120 80 Weather Set Course Set Course Auto heading adjusting success Rudder Counter EE 060 Auto heading adjustment failed The message goes away after 6 seconds In case of correction fails repeat
25. justment maybe required In general an agile vessel with a relatively large rudder or very small keel will require a small rudder setting A large slow vessel may require a high value for the rudder ratio This may also be adjusted according to speed low speeds may require more rudder angle for steering than high speeds e A value of 1 signifies the minimum amount of applied rudder for sensitive steering large rudders or low gearing ratio e A value of 20 signifies the minimum amount of applied rudder for vessels with slow steering small rudders or high gear ratio When the rudder setting is too low turns will take an excessive amount of time and the vessel may wander When the rudder setting is too high turns will be rapid and the vessel will oversteer 1 5 3 Counter Rudder Control In some vessels changing course requires a large amount of rudder to be applied Initially and then a smaller amount of rudder in the REVERSE direc tion to stop the vessel from swinging beyond its desired course This is called counter rudder The KAP 866 Autopilot has this feature built in A counter rudder setting of 1 gives no counter rudder steering suitable for light and manouverable vessels If you find your ship over steering when under autopilot control increase the counter rudder setting by a couple of steps and see if the next course change behaves better Once the correct setting is found for your vessel it should not nee
26. lue for the off course angle ie the one set when the KAP 866 is turned on is 30 degrees 2 2 Installation Menu Press and hold MENU button to enter the Installation menu Rotate the Konb to the desire item and press the knob to enter the that item to make the related change INSTALLATION MENU SELECT REMOTE UNIT SELECT RUDDER FEEDBACK UNIT SELECT MAGNETIC SENSOR UNIT TRIM SETTING AUTO HEADING ADJUST MANUAL HEADING SETTING HEADING ALIGNMENT SETTING LANGUAGE SETTING i 2 2 1 Select Remote Unit There are 2 kinds of option remote units are available from Onwa Hand Remote RT580 and Electric Wheel RW230 Choose either remote unit which is installed Note No remote set up is needed if no remite units 1s installed INSTALLATION MENU 1 HAND REMOTCH 2 ELECTRIC WHEEL Cancel ES C ok EN T 2 2 2 Select Rudder Feedback unit There are 2 kinds of Rudder Feedback units are available from Onwa heavy duty KRF35 and light duty KRF36 rudder feedback unit Choose the correct rudder feedback unit which is installed Usually light duty rudder feedback unit 1s for vessel below length of 50 meters 165 feet Note Choice of Rudder Feedback Unit 1 Heavy Duty Rudder Feedback Unit KRF35 RFUH 2 Light Duty Rudder Feedback Unit KRF 36 RFUS SELECT RUDDER FEEDBACK UNIT ELECT RUDDER FEEDBACK UNIT SELECT MAGNETIC SENSOR UNIT RSs TRIM SETTING AUTO HEADING ADJUST 2 RFUS MANUAL HEADING SETTING 1 Cancel ES C ok EN T
27. n the Knob to change the setting in the setting in the selected item Press the Knob to confirm the setting or press ESC to exit FUNCTION MENU SET RUDDER LIMIT SET TRIM OFF COURSE ALARM STOPWATCH TIMER ALARM 00 2 1 1 Set Rudder Limit There are physical limitations to the angle that the rudder can move through If the autopilot attempts to drive the rudder past these limits damage to the steering gear may occur Setting Rudder Limit is to prevent the rudder from over steer beyond the set limit The Rudder Limit will function before the steering system reach the mechanic limit There are 2 symbols P L Port Limit and S L Starboard limit will appear on the display When you see either of these 2 symbols a When rudder moves excess the set Port Limit or Starboard Limit a P L or S L will appear on the display No port or Starboard rudder movement command will be sent out from the autopilot b The functioning of Starboard Limit S L us same as Port Limit P L Note The factory default setting of Rudder limit is 30 degrees That means if rudder feedback unit is properly installed then when the rudder is moved over Port or Starboard 30 degrees the display will show P L or S L 2 1 2 Set Trim There are circumstances in which the autopilot may set the rudder in the centre according to its feedback unit But the vessel does not steer straight ahead Reasons for this are 1 The rudder may not be perfectl
28. nnect the data output and data output and data return wires of external device to the IN and IN of KAP 866 GPS connector Onwa KGN100 or KGN200 is supplied as an option to convert the analog signa sychro or stepper of gyrocompass onboard to NMEAO183 data as heading source to KAP 866 Digital heading source GPS device 3 7 External Alarm Installation An external buzzer may be connected to the ALA and ALA of KAP 866 Alarm connector The ALA output will be 10 volts when the alarm is not sounding with alarm connected and approximately 0 volts when active We recommends a 12 volt piezo buzzer with maximum current draw not exceeding 250 milliamps be connected to this output If a larger type siren or alarm unit which draws in excess of 250 milliamps is used this must be connected via a relay The KAP 866 external alarm circuit is used to energise the relay coil and power to the siren or alarm unit 1s conn ected via the relay contacts The external alarm output 1s activated if the stopwatch timer has been sounding for longer than one minute External Alarm 3 8 Installation of Remote Units Onw a Hand remote RT580 and Electric wheel RW230 is supplied as an option Sometimes the user require to operate autopilot away from KAP 866 then this time a remote unit is needed The installation of remote
29. one of more than 0 1 NM Nautical Miles is set so that the GPS can detect when the vessel has reached a waypoint then the KAP 866 will be able to steer from each waypoint to the next without intervention If only the XTE information is available from your GPS unit then your vessel must be on track and heading in the correct direction before engaging the GPS mode and the auto sequencing feature 1s not available Remember Prior to engaging Navigator mode a route must be programmed into the GPS for the Autopilot to follow No GPS Data Alarm If the autopilot is not receiving valid information while in GPS Mode the No GPS Data alarm will sound and NO GPS will blink on the display This counld be caused by e Incorrect wiring of the GPS to the KAP 866 e Incorrect data output from the GPS unit e No route set up or selected in the GPS unit e No location fix at the GPS unit The bearings generated by the GPS unit must correspond to the bearings the KAP 866 is receiving from its magnetic compass The greater the difference between these Bearings the less accurate will be the Navigator mode steering e Ensure that the GPS unit has the correct magnetic correction factor e Ensure that the KAP 866 compass is correctly aligned and installed 2 MENU SETTINGS 2 1 Function Menu Press MENU to display the Function menu Turning the Knob to move cursor between the Function menu items Press the Knob to confirm the selection Tur
30. ply Determine vessel heading by a sighting on known heading or compass Align Autopilot magnetic sensor until display reads correct heading Select AUTO mode on control unit CAUTION IF AUTOPILOT DRIVES HARD OVER IMMEDIATELY TURN CONTROL UNIT OFF REVERSE MOTOR WIRES MARKED MOT AND MOT AT THE MOTOR CONNECTOR OF KAP 866 AUTOPILOT REPEAT FROM STEP 1 Turn course knob 10 degrees to starboard Confirm that rudder moves to starboard Turn course knob back to centre then 10 degrees to port Confirm that rudder moves to port Press ST BY key to leave auto mode NOTE AT NO TIME SHOULD THE AUTOPILOT DRIVE THE RUDDER INTO THE MECHANICAL STOPS The autopilot is now ready for full operational testing sea trials Testing should Only be carried out in clear waterways until you are familiar with the operation MAINTENANCE TROUBLESHOOTING 5 5 1 Preventive maintenance WARNING ELECTRICAL SHOCK HAZARD Do not open the equipment Only qualified personnel should work inside the equipment Regular maintenance is important for good performance A maintenance prog ram should be established and should include the following points e Check connectors and ground terminal on the fluxgate sensor unit and dis play unit for tightness e Check ground terminal for rust Clean or replace as necessary e Check for water leakage in the interconnection cable between fluxgate unit and display unit Clean or replace as necessary
31. refully as the internal gimbals can be broken if dropped Remove any internal packing before use The position of this compass is the most important item in the installation of the autopilot Good course holding depends on the compass being free from magnetic interference As this compas s has no moving card it is not necessary for the compass to be mounted low inthe vessel This is usually a place of high magnetic interference and should be avoided However a position of severe roll such as the top of a mast should also be avoided The compass need not b e mounted in a weatherproof position The compass can be mounted on top ofa flat surface on a bulkhead or from the deck head Check other side of bulkhead for materials which may cause magnetic interference Interference from any iron or steel can cause malfunction of the compass unit To prevent this occurring a minimum distance of 1 meter 3 feet should be kept from any steel or other ferromagnetic materials This includes speakers and radios with internal speakers Fasten the compass bracket with non magnetic screws The compass must be mounted in anear vertical position Desktop mounting e only suitable for fiberglass or wooden vessel e To ensure the signal of sailing directions is accuracy please choose a locat ion where vibration and shock are minimal Installed in the surface of platform Bulkhead mounting Only suitable for fiberglass or wooden vessel
32. talled in a place free of magnetic interference and connected to the autopilot via the cable supplied The rudder feedback must be attached to the rudder in sucha way that it can accurately measure the position of the ship s rudder This must also be conne cted to the autopilot via the cable supplied KAP 866 is designed and constructed to meet the rigorous demands of the marine environment However no machine can perform its intended function unless properly installed and maintained Please carefully read and follow the operation installation and maintenance procedures set forth in this manual We would appreciate feedback from you Thank you for considering and purchasing ONWA 1 OPERATION 1 1 Controls MENU Press once Open Activate menu Ship s heading field Press 5 sec Activate installation menu Control field CTRL Select controls setting Mode field KNOB ENT 0 Choose menu item mm D MA Change course heading saunter 4 7 060 Press the Enter ode Qs alt ARROW KEYS e Press once to change one 7 degree course to steer POWER To switch on off the unit To adjust display backlight and contrast Mode Selection ESC Exit menu and operation 1 2 Turning the power on off e Power on Press POWER once to switch on the unit with a beep sound ONWA KAP 866
33. y aligned 2 There may be a side wind current net drag etc which causes the vessel to steer to one side KAP 866 can compensate for these errors but may take a few minutes to core completely Adjusting the SET TRIM can eliminate these Errors immediately To find the correct trim setting With the vessel Travelling ahead switch the autopilot to Standby mode Adjust the trim control until the ship steers straight The SET TRIM is not intended to be used for adjusting the vessel course in Auto or F UP steer mode 2 1 3 Stopwatch Timer Alarm In any mode press MENU to display Function menu Rotate the Knob to move cursor to STOPWATCH TIMER ALARM and press the Knob to confirm Rotate the Knob to change the setting between 0 180 minutes and press Knob to confirm and save setting After setting STOPWATCH TIMER ALARM the countdown will start once AUTO or NAV mode is set when countdown to 0 from preset time the STOPWATCH TIMER ALARM will be triggered a continuously short beep sound and flashing STOPWATCH TIMER ALARM will appear on the display 40 STOPWATCH TIMER ALARM 20 Heading 080 Weather 16 Set Course a The user can press ESC to cancel the alarm and the timer will start another countdown again Once countdown to 0 from the preset time the STOPWA TCH TIMER ALARM will be triggered again The STOPWATCH TIMER ALARM will be carried out repeatedly until either the user

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