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H1000 English Autopilot Install

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1. C19 90 MINIMUM RRU ANGLE AL PARALLEL Z Page 10 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation rudder reference unit The rudder hardover angle should only be limited by the rudder stops not the rru linkage or pilot drive unit Check that when hardover the rru arm and drag link do not form a straight line If this occurs the steering system could become damaged or jammed endangering the boat and crew This fault can easily be rectified by adjusting the position of the RRU linear feedback unit Where installation of the conventional rudder reference unit is difficult or physically impossible a linear feedback unit SEN RUD LFB can be used The linear feedback unit comprises of a tube approximately 23mm 7 8 inch in diameter and 300mm 12 inch long This assembly is attached to the top of the B amp G Blue Ram Types T1 or T2 Each end of the linear feedback unit has a small rose joint which is attached to corresponding pillars on the ram the rose joints are retained using washers and spring clips LINEAR FEEDBACK UNIT T lj Ll New H AQ D Page 11 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot rudder drive options warning Accurate performance of the yacht s steering sys
2. 44 0 1590 689699 h1000 pilot calibration calibrating the pilot Calibration With the system ON press Mid and select calibration calibration menu The procedures for calibration can be divided into two sections The first is carried out at the dockside Dockside Calibration and the second is carried out or checked during the course of a sea trial Sea Trial Calibration Calibration p Pilot dockside Pilot sea trial Securitv pilot calibration parameters The following is a list of the pilot calibration parameters that must be set for successful pilot operation Rudder amidships Set the rudder amidships position Boat lag Set the boat lag value Rudder gain Set the rudder gain value dockside calibration The following parameters must be set prior to a pilot sea trial The procedures to do this are described in this section of the manual Boat type Rudder stop port Rudder stop stbd Drive type Hardover time Waterline length J oystick control Page 53 www bangservice co uk 44 0 1590 689699 calibration dockside calibration h1000 pilot Dockside Rudder stop port Rudder stop stbd Dockside Boat type Rudder stop por Rudder stop stbd Dockside Boat type Rudder stop port Rudder stop stbd Dockside Rudder drive type Rudder hardover time Boat waterline length Magnetic dip angle Joystick control www bangservice co uk selecti
3. Mounting Bracket Sealing Ring Pilot Display Fitted at Manufacture Unit i O Protective Cover NS i RI 71 RI Page 5 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot h1000 compass unit a 99 5 e li 75 10 description The h1000 compass is an electronic fluxgate for use with all h1000 systems The unit is housed in a sealed casing constructed of high impact plastic It is therefore suitable for on or below deck mounting If installed in a vessel with a steel or reinforced concrete hull it may be necessary to install the compass unit outside the magnetic screening affect of the hull and super structure Two Fastnet connectors are provided at the base of the unit These connectors allow connection to the rest of the system for the supply of power and data siting the compass unit Mount the compass upright on a flat vertical bulkhead where it will be e A safe distance from external magnetic interference 3m 10ft from VHF RDF loudspeakers depth sounders engines or power cables carrying heavy current 3m 10ft from radar and SSB equipment Externally mounted on steel vessels Protected from physical damage Protected from water ingress particularly bilge water Optimum positioning as low as possible to minimise effect of pitching and rolling of
4. RAP ROD END N WASHER d _ TILLER BOLT J R3773 p y 16MM MAX LOCTITE RECOMMENDED 12MM e QUADRANT THICKNESS MIN WASHER NUT TORQUE 27NM 20 Ft lb Page 16 44 0 1590 689699 www bangservice co uk h1000 pilot description installation size 3 hydraulic ram drive dimensions 24V L OL uuycz 304mm 12 0 20mm 0 79 o at S o E S E E LO e S SE a e o NI E E D gt o o amp E cguugoz gt E E 5 to S 5 0 p uzo uU og 25 str Page 17 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot type 3 ram bolt detail 82 0 WWO OZ O LO lt r x o lt o gt E N W q 100 6mm 3 96 27 0mm 1 06 8 0 uuug 6g 15 2mm 0 6 x CHF Page 18 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation ram drive unit installation Note General consideration must be given to the steering system and its geometry before starting the installation Many factors must be contemplated for a practical solution the information given here is for guidance only although where a maximum or minimum value is given this must be adhered to It is essential that the unit be installed in a fully functional steering system with no backlash or stiffness when operating Rectify any steering problems before installation of the ram drive unit or the autopilot will not function corre
5. h1000 pilot Midstroke 429mm 16 9 223mm Page 14 www bangservice co uk Stroke Length 203mm 8 0 GN D Ji ol Bill 360 Movement xd 4 off Mounting Holes gt 9mm Dia at 76mm Centres 76mm 66 7mm q q A AO 125 6mm Ne FZ 73 3mm I x es y 109 gt 16mm 12mm Dia 0 0 018mm 44 0 1590 689699 h1000 pilot description installation 252mm 9 9 4 mounting holes 9mm at 76mm centres hydraulic ram drive dimensions T1 12V T2 12V T2 24V 9 i N t8 WWE LZ 21mm 0 83 701mm 27 6 Mid stroke 575mm 22 7 Lo CH l CH Ir Ces ure 4 9 222mm 8 7 Page 15 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot type 1 and 2 rose joint and am bolt detail 100 3mm 3 95 87 6mm 3 45 58 2mm 2 29 49 0mm 1 93 22 6mm 0 89 30 0mm 1 18 Set 20 0mm 0 79 U CUT 6 4mm 0 25 y 3 0mm 0 12 16 0mm 0 63 16 0mm 0 63 12 0mm 0 47 g M8x1 25P 6G 211mm E 0 83 15 2mm 0 6 x 45 12 0mm 0 47 LI 12 2mm 0 48 gj I 6 4mm 0 26 10 2mm 0 40 x45 6 6mm 0 26 CHF M12 x 1 75P CLASS 6g 7 9mm 0 31
6. EXCELLENCE IN MARINE ELECTRONICS a A Simrad Company CAUTION Use of solvent based or chemical cleaners on the displays will result in damage and invalidate the warranty h1000 pilot installation manual HB 1000I 02 English WARNING An autopilot is a very useful navigational aid but DOES NOT under any circumstance replace a human navigator Do not use automatic steering when e _ n heawtraffic areas or in narrow waters e n poor visibility or extreme sea conditions e When in areas where use of an autopilot is prohibited by law When using an autopilot Do not leave the helm unattended Do not place any magnetic material or equipment near magnetic or fluxgate compass used in the autopilot system Verify at regular intervals course and position of vessel Always switch OFF the autopilot in due time to avoid hazardous situations www bangservice co uk 44 0 1590 689699 h1000 pilot contents contents contents 1 h1000 pilot display 4 description 4 siting the pilot head 4 mounting procedure 5 panel mounting 5 h1000 compass unit 6 description 6 siting the compass unit 6 mounting procedure 6 rudder reference unit rru 7 description 7 key points when installing the rru Fi linear feedback unit 11 rudder drive options 12 ram drive unit 12 description 12 hydraulic linear drives 12 hydraulic ram drive dimensions TO 12V 14 hydraulic ram drive dimensions T1 12V T2 12V T2 24V 15 size 3 hydraulic ram drive dimen
7. 5 Recalibrate pilot and contact the nearest B amp G dealer for advice no rudder position fault description Signal from the rudder reference unit is outside the limits set during calibration check list 1 Check installation of rudder reference unit for slack or loose fittings 2 Check wiring and the signal from the rudder reference with a volt meter at the pilot computer terminals The voltage supply to the rudder reference should be 4 5 to 5 0V between red blue With someone moving the helm the signal measured between blue green should change smoothly If the signal is incorrect suspect a faulty rudder reference unit Note the difference between the signal voltages measured at the two end stops must be at least 1 0V e g blue green voltage minus red green voltage must be greater than 1 0V 3 Set pilot display to show digital rudder angle in degrees Move helm to port and starboard end stops check that the indicated rudder angle is 40 42 If not check the rudder reference installation to determine and rectify the reason for the end stop position changing and then re enter the end stop calibration values 4 Move helm slowly from end stop to end stop Check that indicated rudder angle counts from 40 one side to 40 the other side without missing a count 5 _ If the fault is always at the same rudder angle suspect a faulty rudder reference unit 6 If the fault is at different rudder angles suspect a fault in the
8. manual rudder gain Steer the boat onto a suitable heading and allow time for the boat to settle on this course Select Compass Mode by repeatedly pressing the MODE key Press the ON key on any h1000 pilot display or hand held controller The autopilot will now steer the boat on the selected heading At a speed not exceeding 15 knots make course changes of at least 120 by multiple presses of the 10 course change buttons on any h1000 pilot display or hand held controller Observe and estimate the rate of turn It should be approximately 7 to 8 per second To estimate the rate of turn the display is updated every 1 second therefore the heading display should jump in 7 to 8 steps 7 Observe the performance of the pilot when changing course 8 If the rudder gain value is too low the autopilot will understeer causing sluggish steering If the rudder gain value is too high the autopilot will oversteer causing erratic steering and excessive rudder movements In high speed boats this could cause a jerky response and dangerous rates of turn 9 Adjust the rudder gain value for best steering performance Use the minimum value necessary to maintain a good response to course changes and course keeping without excessive rudder movement UBUN R o Rudder Gain setting the rudder gain manually The autopilot must be disengaged and Sea Trial calibration mode selected to adjust the rudder gain value Rudder gain
9. no boat speed fault description The boat is stationary or moving very slowly less than 1 5 knots or the speed sensor is not working check list 1 If boat speed for pilot comes from instrument system check speed shown h1000 display or pilot display 2 If boat speed connected directly to pilot check connections 3 Check boat speed sensor for correct operation no heading data fault description Compass data from the h1000 compass NMEA via Fastnet or gyro input into the ACP has stopped or become unreliable check list 1 Check heading display on pilot display unit 2 Check connections from compass sensor to the h1000 Fastnet 3 Check gyro sensor and wiring if compass data is from an external device 4 Check NMEA heading data and wiring if compass data is from an external device Page 62 www bangservice co uk 44 0 1590 689699 h1000 pilot troubleshooting troubleshooting no nmea information fault description The pilot has stopped receiving waypoint data from the position fixer check list 1 Check cross track error display on pilot display or h1000 display 2 Check connections to pilot system 3 Check operation of position fixer Has NMEA output been selected and enabled Has autopilot output been enabled Does the position fixer have a fix Refer to position fixer manual nmea data unstable fault description The value of cross track error data being received has suddenly changed by more t
10. 1 Blue Wire Pin 2 Brown Wire 6 The cable screen must be cut back and sleeved Refit the two halves of the connector together tighten the plastic cable clamp nut replace the rubber seal and fit the connector onto the solenoid using the centre screw to fully secure it Page 38 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation hydraulic pump connections DRIVE DRIVE SUPPLY SUPPLY IN OUT uk aye J Heavy Duty Power Supply Eh Black Rudder Reference Unit RRF ACP Red Circuit Breaker 1 o o e ES lo o r S 2 os 0 0 0 0 EI E A g lt S Hydraulic Pump RAM T1 12V RAM T2 12V RAM T3 24V Page 39 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot continuous drive unit connections These are general wiring instructions only showing the implementation of the ACP outputs to drive the continuous drive pump solenoid valves The continuous drive pump motor will also require a heaw duty supply which is not provided However suitable units can be obtained from your dealer Clutch output is used to control the motor supply Note The ram solenoid must be designed to operate at the same voltage as the pump DRIVE DRIVE SUPPLY SUPPLY IN OUT BR 4 Al olf BL
11. 19 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot layout of a typical ram drive unit Rudder in amidships position c offset b tiller arm 0 approx 88 length defined by dimensions un A dod eee SA ROME Ee AA FO The ram arm must be atthe FT mid point of its travel Centre line of vessel a half max rudder angle midstroke length gt The ram rose joint will allow a maximum of 9 mis alignment L Se EE c manna d i VH 90 Construct a platform for the mounting plate so that the ram is at 90 to the rudder stock Rudder stock and steering gear assembly Page 20 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation ram mounted parallel to vessel s centre line Rudder in midships position c offset N N 2 WS a filler arm length a half max rudder angle Thera skuld beat right angles to the tiller arm approx 88 defined by Centre line of vessel RE midstroke length The ram arm must be at the mid point ofits travel Y Page 21 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot ram mounted parallel to vessel s centre line key points on installation e Make sure that the rudder angle is limited by the rudder stops and not the limit of travel of the ram arm Failure to comply will damag
12. T2 12V RAM T2 24V RAM T3 24V h1000 Processor Colours Linear Feedback Colours dee EE 5V Supply ees ee OV Supply Signal Wiper Page 42 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation non B amp G paddle connection Any non B amp G speed sensor used with this system must have a speed signal output from a hall effect device giving positive pulses of 12V maximum 1 Locate the cable from the speed sensor to the instrument input 2 _ Cut cable if necessary and insert a junction box B amp G part no 288 00 001 Connect like colour to like colour 3 Use a length of 2 core screened cable B amp G part no 135 0B 098 9m 30ft to connect the speed signal and ground of the paddle sensor to the speed input of the ACP computer unit 4 Calibrate the speed input in accordance with the instructions given in the Speed Calibration section of the h1000 System User manual Non B amp G Display TOU DJ F G Non B amp G Paddle Unit ACP Boat Speed Function Cable Terminals 135 0B 098 Speed signal input Red Neued Notused Silver Screen Screen Page 43 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot furuno ad10 heading
13. When viewed in elevation the ram drive arm and rudder reference unit drag link must not be more than 39 from horizontal Ideally all components should be horizontally aligned as this prevents excessive stress during operation Page 8 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation rudder reference unit Rudder in midships position o The drag link should be at see text right angles to the tiller arm Centre line of vessel The drag link ball joints will allow Rudder stock and steering a maximum of 9 mis alignment gear assembly A A T gt aA FF X o F 90 i Construct a platform for the RRU so that the drag link is at 90 to the rudder stock UN II Page 9 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot rudder reference unit The RRU can be mounted in a variety of positions and orientations depending on the layout of the steering system see text drop gu If the maximum rudder angle is less than 90 then the position of the RRU or the drag link must be adjusted so that the operating arm of the RRU swings through a minimum of 90 1V minimum variation
14. base of the unit i e the connection and terminal blocks Disconnect the cables between the two halves of the casing Firmly push the two halves of the computer unit apart Using the base of the unit as a template mark the positions of the three mounting screw holes Using the self tapping screws provided secure the base of the unit in position Push the two halves of the unit together again and reconnect the cables Page 30 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation acp unit installation cable and connection information emc compliance B amp G equipment is designed to be operated in leisure craft Every care has been taken in its design and testing to ensure compliance with the European EMC Directive provided it is installed and operated in accordance with the instructions as supplied and the units and cables used are unmodified Specific attention is drawn to the requirements to maintain cable separation where stated Transmissions from poorly installed or maintained Single Sideband equipment may adversely affect the functioning of this equipment On vessels fitted with SSB it is essential that such equipment is installed following good installation practice and as recommended by the manufacturer general wiring notes e Do not apply power to the pilot system until all units are connected and the wiring has been checked e Where spade connectors are supplied always use the correct crimp
15. checked during the initial sea trial Compass Swing Rudder Amidships Boat Lag Rudder Gain The sea trial calibration should be carried out in open water on a calm day The procedures for the remainder of the calibration involve continual course and speed changes It is very important to maintain a constant lookout at all times Use proper seamanship when clearing turns to ensure the calibration is carried out safely The autopilot will be initially operating from the factory default values for boat lag and rudder gain During the sea trial the pilot learning algorithm will automatically set and adjust the value for rudder gain The values for boat lag and rudder gain will be checked and adjusted to finely tune the autopilot steering performance when necessary The default values are automatically set depending upon the type of vessel selected under boat type Page 57 www bangservice co uk 44 0 1590 689699 calibration h1000 pil ot compass calibration The Compass Calibration Menu sets the heading offset damping and swing parameters for the h1000 fluxgate compass compass offset The compass offset electronically compensates for fixed errors misalignment between the fluxgate sensor and the direction of the boat These errors will occur since the compass can be mounted in any orientation within the boat To accurately enter a compass offset the boat s actual heading must be known for example reference the h1000 fluxgate ag
16. connection po o 0 0 U AD10 Cut back unused wires E ES Furuno AD10 Output Cable Furuno AD10 Compatible Display Page 44 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation INTENTIONALLY LEFT BLANK Page 45 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot hand held controller 56 5mm 24 0mm ee SS 1 auto resume 128 0mm off BEG description The hand held remote controller is a weatherproof unit that has six function buttons and a status LED to indicate the operating mode of the autopilot The unit provides palm of the hand control of the pilot The cable has a 10m 30ft straight section plus a coiled length that extends from 1m to 3m siting the hand held unit e Ataconvenient position within easy reach by the crew e Ensure at all times the hand held remote controller s cable cannot become snagged on any moving parts e g throttle controls mounting procedure e Heavy duty self adhesive Velcro strip is supplied with the unit e Clean and de grease the site stick the Velcro firmly in place Page 46 www bangservice co uk 44 0 1590 689699 h1000 pilot optional devices man overboard button mob M30x 1 5 41 m 30mm 40mm 44mm description The man overboard MOB button is a large red weatherproof press swi
17. description The reversible hydraulic drive pump has a small high speed pump driven by a 12V or 24V dc permanent magnet motor The pump has pilot check valves to prevent back driving and a pilot operated reservoir valve to enable the unit to drive balanced or unbalanced cylinders The unit has port and starboard Vainch BSP service ports and a Vainch BSP reservoir port pump data dc motor dc motor dc motor Typical Operating Current 5A to 17 5A 5A to 22 5A 6A to 17 5A Range 1000 psi Maximum Flow Rate 750 cc min 1420 cc min 1980 cc min at continuous duty motor 46 in min 87 in min 121 in min loading 6 1 to 18 3 in 16 8 to 33 6in 32 to 46ir 6 6 Ibs 6 6 Ibs 8 8 Ibs key points on installation A position should be chosen convenient for the steering system hydraulic delivery lines The site should be rigid and flat to prevent excess vibration Shielded from the direct effects of the elements Minimise the lengths of the hydraulic lines from the pump to the cylinder and where possible the pump motor supply cables Page 25 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot hydraulic drive pump dimensions type 1 and 2 u v 413 y 4 Q ov 4 holes 7 0mm 80mm 0 28 3 15 y pas y Fa 9 45 88 9mm 598mm C9 200 ae centres type 3 4 holes 6 7 0mm 82 5mm 50 8mm centres centres Page 26 www bangservice co uk 44 0 1590 689699 h1000
18. in the opposite direction and continue in this manner until topping up is no longer necessary 10 When satisfied that the steering is fully bled manually apply power to the pump unit 11 Turning the wheel fully from lock to lock will cause the pump to self purge 12 Check the fluid level in the helm unit reservoir 13 Wnen the system appears to be fully functional with the pump running and the helm hardover check for leaks 14 Secure all hoses and cables to prevent damage Page 27 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot hydraulic drive pump installation examples single station system example HYDRAULIC PUMP UNIT o NU NEU RRU oan AN 1 f O oS d LA Ja d amp gt dual station system example IYDRAULIC DRIVE PUMP lo 1167 HYDRAULIC CYLINDER Page 28 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation hydraulic drive pump installation examples dual station system with bypass example HYDRAULIC DRIVE PUMP o o NU NU 22021 D Xt t Mum N RELIEF BYPASS Q 2 VALVE BLOCK o Ao AN DE JO HYDRAULIC CYLINDER O JO HYDRAULIC CYLINDER Page 29 www bangservice co uk
19. linear feedback connection 42 non b amp g paddle connection 43 furuno ad10 heading connection 44 optional accessories 46 hand held controller 46 description 46 siting the hand held unit 46 mounting procedure 46 man overboard button mob 47 description 47 siting the man overboard alarm button 47 mounting procedure 47 acp joystick 48 description 48 siting the joystick 48 mounting procedure 48 Page 2 www bangservice co uk 44 0 1590 689699 h1000 pilot contents contents h1000 pilot calibration 49 pilot installation checklist 49 drive unit and steering system 49 linear hydraulic rams 49 size 3 ram installation checklist 49 hydraulic pumps 49 rotary drives 49 rudder reference unit installation 50 linear feedback unit installation 50 compass installation 50 electronics installation 50 speed calibration 51 calibrating the pilot 53 pilot calibration parameters 53 dockside calibration 53 selecting the boat type 54 setting the rudder end stops 54 setting the port rudder stop 54 setting the starboard rudder stop 54 selecting the rudder drive type 54 hardovertime 53 waterline length 55 magnetic dip angle 56 magnetic dip angle compensation chart 56 joystick control 56 seatrial calibration 57 compass calibration 58 engaging the h1000 pilot 61 setting the rudder midships position 61 boat lag 61 setting the boat lag value 62 boat lag value table 62 automatic rudder gain 62 checking the automatic rudder gain learning 62 manual rudd
20. message from SOG To accept this value simply highlight OK and press the ENTER key 3 If speed over the ground is not available simply highlight the speed value and using the UP DOWN and ENTER keys adjust the value to the known reference boat speed 4 Next highlight OK and press ENTER to complete the operation sea temperature units Sea temperature information can be shown in c or f To change the units highlight Sea temp and press ENTER Using the UP DOWN keys highlight the desired choice and press the ENTER key to memorise Calibration m ind Compass Securitu Speed Calibration peed Calibration knot knot Damping Q5 Damping kph Adiustment auta diustment mph Sea temp Sea temp Speed Calibration Unit knot MEME 05 Adiustment auto Sea temp peed Calibration Sea temp c OK Speed Calibration peed Calibration Auto Calibrate Auto Calibrate Auto Calibrate Unit knot Unit knot Run Length Run 1 Run 1 Damping 04 Damping 04 aa gt fee auto auto T start nc Sea temp Sea temp 100 Nm c J OK OK abort all abort all Auto Calibrate Auto Calibrate Run 2 Run 2 Start end abortall accept all abort all accept all peed Calibration Reference Speed Auto Calibrate Auto Calibrate Unit knat Run 3 Run 3 Damping 05 RA P hl kt Start end re OK DK abortall accept all abortal accept all Page 52 www bangservice co uk
21. pilot description installation hydraulic drive pump installation Note When dealing with any hydraulic system great care must be taken to ensure that a high degree of cleanliness is observed and no dirt moisture or foreign objects are allowed to enter the system When bleeding your hydraulic steering system only use a good quality ISO10 hydraulic oil e g O8 Dynobear or equivalent 10cSt at 40 C The procedure for installing the hydraulic drive pump is as follows 1 Drain the steering system from the lowest point usually at a cylinder coupling 2 Fit T pieces into the port and starboard delivery lines couple the lines to the appropriate service ports of the pump using flexible hydraulic hose 3 Couple the reservoir port to the reservoir balance line from the helm units A low pressure transparent plastic tube can be used Note Ensure that this line rises gradually with no down turns 4 Refill the steering system as recommended by the manufacturer using clean hydraulic fluid 5 Fill the cylinder by temporarily removing the cylinder couplings and hoses at each end Refit the hoses securely 6 Starting at the highest helm unit fill the helm reservoir 7 Slowly turn the steering wheel two turns to port and then to starboard checking the level of fluid in the helm unit reservoir at all times 8 Next turn the wheel fully in one direction until a slight pressure is felt continuously monitor the reservoir level 9 Repeat
22. rudder gain value table Boat Type Default Value Typical Values Sail Boats 2 00 1 50to 2 20 Power Boats 0 80 0 70 to 1 00 Note the default value is selected by setting boat type and rudder drive type during calibration Page 63 www bangservice co uk 44 0 1590 689699 h1000 pilot troubleshooting troubleshooting trouble shooting introduction The pilot control unit is continually monitoring the h1000 pilot and h1000 system for correct operation If an error is detected the pilot display will show an overlaid error message and the system alarm buzzer will sound if connected To silence the alarm press any of the keys on the pilot display or any h1000 display uncalibrated fault description Rudder not calibrated or memory has been corrupted check list 1 Has rudder ever been successfully calibrated e Yes go to 4 e No go to 2 2 _ Set rudder port and starboard positions Move helm does rudder indicator work e es go to 4 e No go to 3 3 Rudder indicator will not work until port and starboard positions have been entered The difference in the signal from the rudder reference unit at the port end stop and the starboard end stop must be at least 1 0V Check rudder reference installation and then repeat 2 4 _ If rudder has previously been successfully calibrated then fault is due to memory corruption This may be due to memory backup battery failure or severe interference e g lightning
23. there must be at least 1V difference between the end stops sis 3 8 Ball joint securely fixed to quadrant tiller nn g linear feedback unit installation 1 Ensure that the linear feedback unit is attached correctly to the linear actuator using the bracket kit SUM Pll e WEE g 2 Ensure that the ram stroke does not exceed the stroke of the linear feedback umtt O compass installation 1 Clear of sources of magnetic interference including power cables to other equipment If in doubt check 1m around with a small hand compass Look on the other side of the 8 ML ee ss g 2 Fitted as near to centre of motion of boat as other factors allow aft of centre preferred because usually less motion than fore of centre ss 3 electronics installation T Cables STG Aae Ge ERT g 2 Cables UndamMaged WEE g 3 SING ee ME ae g 4 Screens connected in accordance with wiring instructions and sleeved where appropriate 7 Page 50 www bangservice co uk 44 0 1590 689699 h1000 pilot calibration speed calibration Speed calibration sets the units of measurement damping and speed calibration factor units Boat speed values can be shown in knots kph or mph To change the units highlight and press ENTER Using the UP DOWN keys highlight the desired choice and press ENTER to memorise damping Boat speed damping allows you to slow down the response of speed readings in rougher conditions by adjusting the damping value from 0 to 9 Fo
24. to port or to starboard siting the joystick unit Ataconvenient position within easy reach of the helmsman mou nting procedure To ensure correct steering sense the unit is marked with two indents The unit must be installed with these forward The unit requires at least 65mm 2 5 clearance behind the selected mounting position Usea 40mm 1 9 16 hole cutter for the joystick body Ensure the gasket is fitted under the joystick body flange e Secure in place with the self tapping screws supplied e Route the cable to the ACP unit Connect as per instruction detailed in the relevant section of this manual Page 48 www bangservice co uk 44 0 1590 689699 h1000 pilot calibration h1000 pilot calibration pilot installation checklist Before the h1000 pilot can be used it is necessary to set and calibrate various parameters The checklist below should be used prior to the calibration of the autopilot This will ensure that the entire system is correct before applying power drive unit and steering system 1 Drive unit securely fixed to a rigid part of the boat structure eee g 2 Gauge of power cable is appropriate vicodin g linear hydraulic rams 1 Boat end stops must limit the rudder movement not the stroke of the hydraulic ram or RRUO 2 Split pin that holds the pivot pin in the mounting foot is secure g 3 Absence of EN asco dut an Nad ee wi ven a dn a a a ek g 4 Correct diameter bolt in
25. universal ball joint correct size hole in tiller g 5 Ram free to move side to side amp up and down issus 3 size 3 ram installation check list 1 The base foot of the ram and pump have been firmly bolted into position g 2 The reservoir has been fixed to a bulkhead above the ram and pump g 3 The sealed reservoir transit cap has been replaced by the breather cap suptlte g 4 The reservoir has been switched to the ON position VV g 6 Additional reservoir fitted Size 3 only ire g 7 Reservoir at highest point Size 3 only inner g Tap ON position is in line with the pipe The piston rod can now be extended or retracted and the pump run hydraulic pumps T Absenceof oil TEARS EE g 2 Absence of air in the hydraulic steering sise g rotary drives 1 No backlash or excessive slackness in chain sens g Page 49 www bangservice co uk 44 0 1590 689699 calibration h1000 pil ot h1000 pilot calibration rudder reference unit installation 1 Base securely fixed to boat structure iii g 25 Armsecurelyfixed to E g 3 Ball joint securely fixed to arm cuna ii g 4 Linkage has not been over extended iii g 5 No slack or backlash inithe lirlKage u oir site g 6 Linkage does not foul when rudder moved hardover to hardover eese g 7 _ Arm mowes through at least 90 when rudder moved hardover to hardover
26. 44 0 1590 689699 description installation h1000 pilot advanced control processor unit LON AN x ANS ND 1 MOUNTING HOLE CENTRES 89 5 89 5 3 52 AR 3 52 5 33 3 88 98 5 MOUNTING HOLE CENTRES EBS MOUNTING HOLE CENTRE 103 5 103 5 m 4 07 dv 4 07 gt P dU UUuU al 3 54 8 15 E description The Advanced Control Processor ACP Unit contains all the electronics for the autopilot operation and control of the rudder drive options It is designed to be mounted on a vertical flat smooth surface The unit has a hinged lid to provide easy access to the electrical connections siting the acp unit It is recommended that the ACP unit be mounted with the cable entries downwards It must not be mounted with the cable entries uppermost as water may run down the cables and into the unit Ensure that there is sufficient space to allow the unit to be hinged open to make connections to terminals inside and that the hinges of the two halves of the case may be slid apart Select a position sheltered from the direct effects of the environment and from physical damage Do not mount the unit within 1m 3ft of engines starter motors and cables and other cables carrying heaw currents etc or 3m 10ft of Radar or SSB installation cables mounting procedure Undo the two screws at the corner of the unit and open fully The hinges are designed to come apart This enables the electronics to be split from the
27. SIT siv Q HOOD Rudder Reference Unit RRF ACP CNN RAM SOLENOID S Heavy Duty Power Supply RER TP SE Circuit Breaker Black Continuous Drive Pump Solenoid Valves Heavy Duty Power Supply Circuit Breaker Black Page 40 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation direct paddle input connection o T njnjg Cut back unused wires uo ux Please consult your dealer for the specific speed sensor and housing suitable for your vessel Page 41 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot linear feedback connection When the linear feedback unit is used connect the linear feedback unit to the h1000 pilot terminals using the diagram and reference table below DRIVE DRIVE SUPPLY SUPPLY IN OUT BR ol amp SLV ANTON U UOQUY Soe TA EN fee ONGO R glo Y i BL Heavy Duty Power Supply Black f Red mw Circuit Breaker ko E Solenoid a a Connector Linear Rudder Reference Unit SEN RUD LFB e o Hydraulic Ram Drive RAM T1 12V RAM
28. ainst a calibrated bowl compass or follow a known transit referenced from a chart To enter the compass offset value highlight from the Compass Calibration Menu and press ENTER Adjust the value using the UP DOWN and ENTER keys The value entered should be between 180 and 180 Example e _ Boat s actual heading is 076 e h1000 display shows 092 e The compass offset entered should be 016 To facilitate this procedure live heading is shown on the screen so that the effects of the offset can immediately be seen compass damping Compass damping allows you to slow down the response of compass readings in rougher weather by adjusting the damping value from O to 9 For minimum damping set the value to O Increase the damping value if the readings are too unstable in rough weather compass swing The swing procedure allows the compass to learn the effects of any magnetic deviation errors that are unique to your boat The swing should be performed out in open water on a calm day with minimal wind and waves and away from traffic which may require the procedure to be aborted The swing procedure requires the boat to be turned through a complete 360 turn at a speed of less than 5 knots at about 2 per second The entire process should take about three minutes to complete To swing the compass highlight and press ENTER The Compass Swing page will now be displayed with highlighted With the boat settled on its turn press t
29. boat mon nting procedure Secure the unit in the selected site using the non magnetic self tapping screws provided e Route the Fastnet cable to the rest of the system avoiding other cables carrying heavy currents e g engine starter trim tabs etc e Secure cables in place with cable clips or tie wraps e Avoid bending the cable through a tight radius especially near the connector as this may damage the wires inside the cable Page 6 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation rudder reference unit rru 1800 OULU DRAG LINK m 265 0 minimum 1 285 0 maximum TN yr CA tJ 0 2 d M ES M6 stud SCH description The Rudder Reference Unit rru is a sealed high specification potentiometer in a robust casing providing rudder position information to the pilot computer unit The operating arm is constructed from aluminium with three positions pre drilled for the adjustable drag link The drag link has ball joints at each end which connect the unit operating arm to the tiller arm or steering quadrant The unit base has four holes to allow for mounting The unit is supplied with 10m 30ft of 3 core screened cable key points when installing the rru General consideration must be given to the steering system and its geometry before starting the RRU installation Many factors must be contemplated for a practical soluti
30. c 12 or 24V dc 24V dc Supply 1 25A max 1 25A max 1 25A max 0 8A max Peak Thrust 300 kg force 680 kg force 680 kg force 1062 kg force 660 Ibs force 1496 Ibs force 1496 Ibs force 2342 Ibs force Stroke 8 10 10 12 Rod Diameter 12mm 16mm 16mm 20mm 0 472 0 623 0 623 0 623 178mm 214mm 214mm 257mm 70 Rudder 7 8 4 8 4 10 16 545 Nm 1427 Nm 1427 Nm 2688 Nm Torque 4823 65 Ib ins 12574 lb ins 12566 Ib ins 23780 Ib ins 5 8 kg 7kg 7kg 10 3 kg 12 7 lbs 602 15 Ibs 602 15 Ibs 602 22lbs 1102 Helm to Helm Time Extend 10 1sec 15 7 sec 11 9 sec 14 6 sec Retract 9 9 sec 13 4 sec 10 2 sec 12 6 sec 200kg force 200kg force 200kg force 200kg force Page 12 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation rudder drive options The following tables indicate the tiller arm length required for the different types of drives RAM TO Hydraulic Linear Drive Midstroke 429mm 16 9 RAM TO 12V 1 Max Rudder 35 178mm 7 0 RAM T1 and T2 Hydraulic Linear Drives RAM T1 12V RAM T2 12V RAM T2 24V Midstroke 575mm 22 6 1 Max Rudder 214mm 8 4 RAM T3 Split Hydraulic Linear Drive Midstroke RAM T3 24V 755mm 29 7 1 Max Rudder Tiller Arm Angle 257mm 10 2 www bangservice co uk Page 13 44 0 1590 689699 description installation hydraulic ram drive dimensions RAM TO 12V
31. ctly key points on installation Check that the steering gear is in good condition Rectify any steering defects prior to installation of the ram The ram drive unit must be secured onto a flat rigid base It maybe necessary to construct a platform section for the mounting plate For angled rudderstocks an angled platform section will have to be constructed All setting up and aligning of the ram drive unit with the steering system should be carried out with the rudder in the amidships position and the ram arm at the centre point of its travel The angle between the ram arm and the tiller arm should be as shown in the following diagrams The ram arm should ideally be at right angles to the rudderstock The ball joint on the end of the ram arm will allow a MAXIMUM of 39 of vertical misalignment Caution For Type 3 Ram Reservoir Installation do not turn the black reservoir tap on or attempt to move the piston rod until all of the following are completed The base foot of the ram and pump has been bolted into position The reservoir has been fixed to a bulkhead above the ram and pump The sealed reservoir transit cap has been replaced by the breather cap supplied The reservoir has been filled with the oil supplied When the checks listed above have been verified the reservoir tap can be switched to the ON position allowing the oil to flow between the reservoir and the pipe Tap ON position is in line with the pipe Page
32. disengage the autopilot with the red OFF key on any pilot display or hand held controller and return to manual steering Calibration Sea trial Sea trial Speed Depth Rudder amidshi Rudder a Wind d eras shi d ger af Boat lag Boat lag cancel Compass Pilot dockside Rudder gain Rudder gg Set Pilot seatrial Security Sea trial Boat lag Rudder amidships udder gain Sea trial Rudder gain Rudder amidships Boat Rudder 0 50 Page 60 www bangservice co uk 44 0 1590 689699 h1000 pilot engaging the h1000 pilot UBWNE display or hand held controller calibration seatrial calibration Steer the boat onto a suitable heading and allow time for the boat to settle on this course Select Compass Mode by repeatedly pressing the MODE key Press the ON key on any h1000 pilot display or hand held controller The autopilot will now be steering the boat on the selected heading Alter course in multiple increments using the 10 and rotary knob buttons on any h1000 pilot Press the red OFF key to disengage the autopilot and return to manual steering setting the rudder amidships position Due to hull design and steering characteristics the best rudder amidships position can only be set when underway at normal cruising speed Adjust the amidships position as follows d Steer the boat into the wind and maintain a steady course 2 Boats with twin engines must have the engine revs balanced 3 Boats with tr
33. e the unit and invalidate the warranty e Make sure that there is sufficient space at each end for the ram arm to extend fully The ram stroke length is given in the tables on Page 13 of this manual e Check for full movement and security of the steering gear before applying any power to the autopilot system Refer to the installation checklist in the calibration section of this handbook mounting a hydraulic linear ram on a vertical bulkhead Due to the restricted movement of the ram mounting foot base 14 10 for the Size 1 and 2 rams and 5 for the Size 3 ram it is important that the maximum rudder angle is carefully measured and the positioning of the ram tiller arm length and offset are carefully followed from the diagrams on the following page Caution Failure to comply with these dimensions may cause premature failure of the ram and place great stress on the structure of the vessel Note The Size 1 and 2 Linear Rams may be mounted in any orientation without the need to fit an external reservoir The Size 3 Linear Rams requires an external reservoir which must be positioned such that the reservoir is always higher than the drive unit at all normal angles of heel Care must be taken to ensure that the connecting pipes are not in anyway kinked or turned through any tight bends Page 22 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation vertical bulkhead installation Rudder in amidships posi
34. e unit in place However to prevent theft or if removal of the unit is not required then locking studs and thumbnuts are supplied to allow for permanent fixing siting the pilot display head h1000 instruments are designed for mounting above or below decks Select a display site that is At a convenient position within easy reach and view of the helmsman On a smooth and flat surface At a safe distance of 100mm 4 from any compasses Protected from physical damage Accessible from behind for fitting locking studs if required Page 4 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation mounting procedure panel mounting Ensure that the display is installed on a flat surface and there is sufficient room behind the panel to accommodate the fixings and connections Using the template supplied cut a hole in the panel in the desired position Fix the mounting bracket into the hole using the screws supplied Note the sealing ring is fitted to the unit during manufacture its purpose is to prevent moisture penetration and reduce the effects of any vibration transmitted through the instrument panel Press the Pilot Display firmly into the mounting bracket an audible click will indicate that the case is correctly located Secure the unit to the instrument panel by fitting the studs and thumbnuts supplied Caution To avoid damaging the casing fixing studs must only be tightened finger tight
35. er gain 63 rudder gain value table 63 trouble shooting 61 uncalibrated 61 no rudder position 61 no drive selected 62 no boat speed 62 no heading data 62 no nmea information 63 nmea data unstable 63 poor wind data 63 current trip limit 63 no pilot detected 63 pilot not steering a straight course 64 Page 3 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot h1000 pilot display description The h1000 pilot display is designed to be mounted above or below decks The display head allows control of the pilot and by installing multiple display heads gives control at any station It can be connected to all other h1000 Instruments via the Fastnet connectors to provide an integrated autopilot and navigational system Caution it is essential that the pilot is calibrated before operation Details are given in the calibration section of this manual In an integrated system boat speed is supplied from the h1000 Speed Depth Interface and wind speed and wind angle from the h1000 Wind Interface via Fastnet These allow the pilot to operate in the Compass and Wind modes When a CND or NMEA position fixer is connected to the system Navigate mode becomes available NMEA data is connected to the Universal Interface and then broadcast across Fastnet and used by the pilot The display heads are supplied with a clip in mounting bracket which allows for easy installation Access from behind is not necessary to secure th
36. han 0 3Nm check list 1 Check cross track error on display for stability 2 Check operation of position fixer especially signal and noise levels Refer to position fixer manual poor wind data fault description There is no valid wind data being received via the h1000 Fastnet databus or the wind speed is less than 1 knot check list 1 Check wind functions on h1000 digital display or pilot display 2 Check masthead unit connections to instrument system 3 Check NMEA connections to NMEA interface if wind source comes from another instrument current trip limit fault description The voltage or current limit circuit for the drive motor or the clutch has tripped e 12 24V drive motor 25A D Clutch 2A check list 1 Check installation and wiring for short circuits 2 Check current to clutch maximum available 2A 3 Check maximum current to drive motor is less than 25A no pilot detected fault description No regular messages being received by pilot display from pilot computer unit i e either the display is not receiving or the pilot computer is not transmitting check list 1 If other displays show pilot data check installation of pilot display or suspect faulty pilot display 2 lf no pilot data on any display check installation of pilot computer or suspect faulty pilot computer 3 Check installation of h1000 Fastnet cable Page 63 www bangservice co uk 44 0 1590 689699 troubleshooting h1000 pil o
37. he ENTER key to start the swing The display will now show two bargraphs The first is the Progress bar which will fill completely after the boat has been turned through 360 The second is the Turn rate bar which for optimum results should not be allowed to fill completely After completion of the swing the message passed or failed will be shown At any stage during the swing the procedure can be aborted by selecting abort and pressing the ENTER key Page 58 www bangservice co uk 44 0 1590 689699 h1000 pilot Depth calibration compass calibration Speed ind as Compass Cal 274 Offsot 0007 Offset Damping 4 Damping 04 Swing required Swing required Compass Cal 7 D Offset 000 ompass Damping 04 74 Offset 000 Damping 0 Swing required Swing required ompass Ca Heading 274 Compass Swing o Offset DOD Heading 247 Damping 5 secs SMS required Start abort Compass Swing Compass Swing Heading 24 d Heading 6 Note passed is D Progress NEC 1 shown under the Swing title when a successful compass swing has been stored passed OK OK Heading 274 Offset DDOD Damping 3 secs Compass Swing Heading 247 B passed failed OK www bangservice co uk Page 59 44 0 1590 689699 calibration h1000 pil ot seatrial calibration Notes e Ontheinitial sea trial DO NOT EXCEED 15 KNOTS e Always maintain a proper lookout H If in doubt
38. he boat is in line with the second marker of your measured distance press the ENTER key to temporarily halt the calibration Run 2 and will now be shown on the screen 5 Maintaining your constant boat speed turn the boat through 180 in preparation for your second run along the measured distance When the boat is in line with the second marker press the ENTER key to resume the calibration procedure The display will now show RUN 2 and BS will be highlighted 6 When the boat is in line with the first marker press the ENTER key This will temporarily halt the calibration procedure 7 Repeat the procedure detailed above for Run 3 8 Upon completion of Run 3 highlight and press ENTER The system will now automatically calculate the new boat speed and update the readings accordingly Page 51 www bangservice co uk 44 0 1590 689699 calibration h1000 pil ot speed calibration adjustment ref Reference speed adjustment allows for quick and easy calibration of your boat speed readings against a known calibrated source for example speed over the ground from a GPS or alongside another boat with a calibrated log 1 From the Speed Calibration Menu highlight BEIS select Ej from the drop down box and press ENTER to select The display will now show the Reference Speed page 2 If speed over the ground data is available on the system from a GPS the h1000 will automatically detect this and display this value on the screen with the
39. he following points must observed before carrying out the procedure e If the boat is equipped with hydraulic power assisted steering the engines must be running when setting the rudder end stops and measuring the hardover time Move rudder to midships position Highlight the START command Keep clear of the wheel Press the ENTER key to start test The rudder hardover to hardover time can only be calculated with the boat stationary Dockside Rudder drive type Rudder hardover time Boat waterline length Magnetic dip angle Joystick control OK www bangservice co uk If during the hardover timing the rudder does not move check e _ The boat speed is less than 3 knots e The rudder reference unit must move through an angle of at least 90 when the wheel is turned from hardover to hardover e The output variation from the rudder reference unit is greater than 1V from hardover port to hardover starboard e Refer to the installation section for the rudder reference unit and check the installation e The separate power supply to the ACP control unit is switched on waterline length Boat waterline length must be entered into the autopilot for it to steer accurately This value can be entered in metres or feet Page 55 44 0 1590 689699 calibration dockside calibration h1000 pilot magnetic dip angle for boats faster than 20 knots only All magnetic compasses are effected by Northerly tur
40. im tabs must have them in the normal cruising position 4 Select Rudder midships from the Sea Trial menu and choose H3 from the drop down menu Boat Lag Incorrect boat lag Boat lag is the time taken for the boat to respond to Boat Lag Correct www bangservice co uk 1 2 changes in helm For example heavy displacement hulls require a larger value for boat lag Engage the autopilot as previously explained in Initial Pilot Sea Trial At a reasonably slow cruising speed do not exceed 15 knots change course by 90 in each direction Observe the autopilot steering performance The boat should turn onto the new heading with minimal overshoot a slight overshoot is acceptable If the overshoot is consistently more than 5 for course changes in both directions increase the boat lag value in steps of 0 1 until the overshoot is corrected It is easier to observe overshoot than undershoot hence if no overshoot is observed decrease the boat lag in steps of 0 1 until a small overshoot is seen Use the smallest value of boat lag to stop overshoot Page 61 44 0 1590 689699 calibration h1000 pil ot seatrial calibration setting the boat lag value The autopilot must be disengaged to adjust the boat lag value boat lag value table Default Value Typical Value Sail Boats 0 30 0 3 to 1 0 Power Boats 0 50 0 3 to 1 0 automatic rudder gain When the h1000 pilot is part of an integrated h1000
41. ing tool to attach them to the cable This is extremely important where high currents are to be passed i e rudder drive unit Supply cables e Keep supply cables as short as possible to reduce the possibility of a voltage drop in the cables e _ Always fit a fuse or circuit breaker in supply cables It is recommended that heavy duty power cables are protected by a 25A MCB e Clearly identify each cable to prevent incorrect connection e Cables that have a screening braid must have the screen connected as shown on the connection diagrams e Al Pilot cables should be routed at least 1m 3ft from cables or components that carry or generate high currents e g alternators starter motors trim tab cables etc e To minimise interference avoid routing Pilot cables alongside high power radio or radar cables e _ To prevent damage to cabling always secure in position using cable clips or tie wraps Where cables pass through bulkheads always protect the cable from chafing by fitting grommets e Do not allow cables to rest in the bilges where prolonged immersion in water fuel etc may occur e Always fit splash covers and lids on processors computer units and junctions boxes where supplied Page 31 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot pilot drive unit cables all rudder drives heavy duty power cables Total Cable Length B amp G Cable Copper Area Cable Gauge Part No Up to 8m 26f
42. ng the boat type There are three selections available e Sail for all sail boats e _ power disp for power boats with displacement hulls e power planing for power boats with planing hulls setting the rudder end stops Before the h1000 pilot can be used it must know the position of the rudder end stops setting the port rudder stop Move the rudder to the hardover port position Press the ENTER key and select set to store the port position setting the starboard rudder stop Move the rudder to the hardover starboard position Press the ENTER key and select set to store the starboard position selecting the rudder drive type Depending upon the type of rudder drive unit fitted the pilot controls the rudder drive motor in different ways This optimises the autopilot steering response There are four selections available L normal Ram drives hydraulic pumps rotary drives all sizes and voltages 2 pedestal Pedestal drive motors fitted by some steering gear manufacturers 3 outdrive Outdrive drive units and continuous drive units 4 special Proportional drive systems 44 0 1590 689699 h1000 pilot Dockside Rudder drive type Rudder hardover time Boat waterline length Magnetic dip angle Joystick control OK calibration dockside calibrations hardover time To finish the rudder end stop calibration procedure the autopilot must calculate the rudder hardover port to hardover starboard time T
43. ning errors in the Northern Hemisphere or Southerly turning errors in the Southern Hemisphere which increase with boat speed and magnetic dip angle in higher latitudes These can cause heading instability at boat speeds greater than 20 knots when steering with an autopilot By entering the dip value indicated on the compensation chart the autopilot will be able to correct for these errors and improve the heading stability Use the minimum value necessary to stabilise the heading magnetic dip angle compensation chart Dockside Rudder drive type Rudder hardover time Boat waterline length Magnetic dip angle Joystick control OK Page 56 www bangservice co uk joystick control The joystick is an optional device that allows direct control of the rudder There are two joystick operating modes available to the helmsman Normal the rudder moves in the direction of the joystick When the joystick returns to the central position the rudder movement stops The greater the movement of the joystick the faster the response of the rudder Proportional the position of the rudder follows the position of the joystick When the joystick returns to the central position the rudder returns to its initial position Note Until all parameters have been set or checked the autopilot should not be used to steer the boat 44 0 1590 689699 h1000 pilot calibration seatrial calibration The following parameters should be set and
44. on The information given here is for guidance only although where a maximum or a minimum value is given these must be adhered to Mount the rru on a flat surface next to the tiller arm or steering quadrant construct a small platform if necessary Do not lengthen the drag link arm as this can transmit excessive vibration loads to the rru and will invalidate the warranty The unit operating arm can be rotated through 360 the mid point of the potentiometer travel is when the operating arm is opposite the cable entry point When the rudder is moved from hardover port to hardover starboard the rru arm should swing through a minimum of 90 This will ensure that there is sufficient voltage swing to the autopilot Page 7 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot rudder reference unit Measure the voltage difference between the green and blue wires of the rru there should be a minimum of 1V d c change from hardover to hardover Note If there is less than a 1V d c change the pilot will not commission e After installation check full movement of the steering system ensuring that there is no fouling between the steering gear rru parts and drive unit e _ Ensure that there is no backlash in the linkage between the rru and the steering gear otherwise incorrect operation of the autopilot will occur The example shown overleaf is a plan view of a typical system with a tiller arm and guadrant
45. oystick and Button 545 00 060 h1000 pilot Handheld Controller PLHH ACP 44 0 1590 689699 h1000 pilot description installation hydraulic ram drive connections DRIVE DRIVE SUPPLY SUPPLY IN OUT BR ys S BL 8 ANN LARA SI SIV io Qualueue ONOONO R lo mH BL Vi Heavy Duty Power Supply Black Rudder Reference Unit RRF ACP Red Circuit Breaker x ol 3 D m c Solenoid Connector M FF TO J Hydraulic Ram Drive RAM TO 12V RAM T1 12V RAM T2 12V RAM T2 24V RAM T3 24V Page 37 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot ram solenoid wiring details the following information applies to the size 0 1 2 and 3 blue rams only Remove the solenoid wiring connector by unscrewing the centre screw Remove the screw from the connector housing Remove the rubber gasket Use a small screwdriver through the screw hole to carefully push against the connector block This will push the front of the connector block out ready for wiring Run the cable through the cable entry in the cover and then connect as follows RUNE ul Pin
46. r minimum damping set the value to 0 for maximum damping set the value to 9 adjustment Speed adjustment calibration is necessary to compensate for hull shape and paddlewheel location on your boat For accurate speed and log readings it is essential that the paddlewheel is calibrated adjustment auto This procedure will automatically calibrate the boat speed and log readings and is the recommended method for most boats This procedure requires the boat to make consecutive runs under power at a constant speed over a known distance Select two markers that are easily identifiable on the ground and on a chart and where the effects of tidal flow is at a minimum Measure and record the distance between the markers on the chart It is recommended that three runs are carried out this accounts for tidal efforts and improves accuracy However a time should selected when the current is ata minimum i e slack water between tides 1 From the Speed Calibration Menu highlight choose B IS from the drop down box and then press the ENTER key to confirm 2 If necessary adjust the Run Length to correspond with your measured distance and then highlight 6 and press ENTER to accept 3 The display will now show Run 1 and will be highlighted Maintaining the boat at your constant speed press ENTER when the boat is in line with the start of your measured distance The display will now change to show Run 1 with end highlighted 4 When t
47. sions 24V 17 ram drive unit installation 19 key points on installation 19 layout of typical ram drive unit 20 ram mounted parallel to vessel s centre line 21 key points on installation 22 mounting a hydraulic linear ram on a vertical bulkhead 22 vertical bulkhead installation 23 splitting the ram drive unit 24 type 1 and type 2 units 24 type 3 units 24 hydraulic drive pumps 25 description 25 pump data 25 key points on installation 25 hydraulic drive pump dimensions 26 type 1 and 2 26 type 3 26 hydraulic drive pump installation 27 Page 1 www bangservice co uk 44 0 1590 689699 contents h1000 pil ot contents hydraulic drive pump installation examples 28 single station system example 28 dual station system example 28 dual station system with bypass example 29 dual station pressurised system example 29 advanced control processor unit acp 30 description 30 siting the acp 30 mounting procedure 30 cable and connection information 31 emc compliance 31 general wiring notes 31 all rudder drives heavy duty power cables 32 linear drives clutch valve cables 32 acp unit terminal details 32 wire colour coding and abbreviations 32 wiring connections 33 clutch voltage selection 33 acp dip switch location 34 h1000 and alarm connections 35 hand held mob and joystick 36 hydraulic ram drive connections 37 ram solenoid wiring details 38 hydraulic pump connections 39 continuous drive connections 40 direct paddle input connection 41
48. system boat speed data is supplied via the Speed Depth Interface unit This allows the autopilot to automatically learn the correct value for rudder gain by monitoring boat speed and rate of turn The rate of turn will be approximately 7 5 per second If there is no direct speed input or the speed is being set by the manual speed band selections then the rudder gain value must be entered manually Refer to Manual Rudder Gain checking the automatic rudder gain learning Steer the boat onto a suitable heading and allow time for the boat to settle on this course Select Compass Mode by repeatedly pressing the MODE key Press the ON key on any h1000 pilot display or hand held controller The autopilot will now steer the boat on the selected heading At a speed not exceeding 15 knots make at least six large course changes of at least 120 by multiple presses of the 10 course change buttons on any h1000 pilot display or hand held controller This enables the autopilot to learn the rudder gain value 6 When the autopilot has learnt the rudder gain value the rate of turn will be approximately 7 5 per second To estimate the rate of turn the display is updated every 1 second therefore the heading display should jump in 7 to 8 steps 7 _ Press thered OFF keyto disengage the autopilot and return to manual steering Ui PUNA Page 62 www bangservice co uk 44 0 1590 689699 h1000 pilot calibration seatrial calibration
49. t troubleshooting pilot not steering a straight course fault description The pilot seems unable to steer straight it continually overcorrects course errors the wake has an S like appearance as the boat first steers several degrees off course to port followed by several degrees off course to starboard check list 1 Drive unit check for any slack or backlash in the drive system 2 Rudder reference check for any slack or backlash in the assembly and associated linkages 3 Boat speed check that the boat speed input is operating correctly 4 Settings read the calibration section carefully and check that the settings are appropriate for the type of boat 5 Rudder gain make large course changes using the pilot If the gain value is correct the rate of turn should be between 6 and 8 per second Adjust if necessary 6 Boat lag a boat lag value which is too small for the boat can cause instability Try increasing the value 7 Check location of compass sensor in vessel Ensure that the sensor is not affected by the proximity of cables carrying heaw currents loudspeaker magnets or ferrous metals www bandgservice co uk www bangservice co uk 44 0 1590 689699
50. t 135 0A 128 4 0mm 12 awg Up to 12m 40ft Not available 6 0mm 10 awg Up to 20m 65ft Not available 10 0mnv 7 awg linear drives clutch valve cables Up to 9m 30ft 135 0C 096 0 5mm 22 awg Up to 15m 50ft 135 0B 096 acp unit terminal details CLUTCH QUOUQUO DRIVE DRIVE SUPPLY SUPPLY IN OUT MOB HANDHELD AD10 OUTPUT JOYSTICK YIGAANY g o 09 0 0 0 0 0 0 0 0 0 01 ALARM DD ng gf gg gn DO fU ee 0 0 0 0 0 0 0 0 L Don Dag afo ng gn Od wire colour coding and abbreviations Wiring Colours OR JRed LN et J BL Bue H range k BR X Brow w wne Silver Not Used Page 32 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation clutch voltage selection The h1000 pilot computer unit can output different clutch solenoid voltages depending upon the size of rudder drive unit fitted The clutch solenoid valve is only required for rams or rotary drive units This is achieved by setting dip switches on the computer drive PCB Access to the switches is obtained b
51. tch supplied with 15m 45ft of two core screened cable Operation of this button will start the MOB sequence of operations if fitted an audible alarm will sound when the button is pressed siting the man overboard alarm button Selecta suitable bulkhead easily accessible to all crew in an emergency mounting procedure With a 32mm 144 hole cutter cut a clearance hole for the button body Remove the nut and washer then carefully feed the cable through the hole ensuring that the sealing gasket is in place to prevent moisture ingress e From behind the bulkhead feed the washer and nut over the cable and tighten the nut onto the switch body Page 47 www bangservice co uk 44 0 1590 689699 optional devices h1000 pil ot acp joystick 4 Oo A 36 an A View from underside 31 8 Dia Forward indicator marks 70 0mm A 48 0mm i dia 40 0mm 35 0mm le 45 0mm 4 holes dia 3 0mm 290mm gt yY 48 0mm description The joystick allows direct control of the rudder via the autopilot control electronics The unit is deck mountable allowing it to be used both above and below decks A 10m 30ft 3 core screened cable is used to connect the unit directly into the h1000 ACP unit J oystick steering is engaged and disengaged with the separate red button which should be mounted in the same manner as the MOB button at a location close to the position selected for mounting the joystick The lever can only be moved
52. tem is crucial to the safety of you and your crew B amp G always recommend that an Authorised B amp G Dealer performs the installation of autopilot drive units caution In line with B amp G s policy of continuous product improvement drive units are regularly updated Installation data included with your drive unit will replace installation data contained in this manual Before undertaking any shipwright work onboard the yacht it is essential that the installation data in this manual be verified against your drive unit If in doubt consult your authorised B amp G Dealer for technical assistance B amp G cannot accept liability for differences that may occur between the drive unit and this User Manual ram drive unit description A hydraulic pump driven from the dc electric supply combines a compact reversible pump and a hydraulic cylinder assembly for use on boats without hydraulic steering systems Three sizes of ram drive units are available giving a wide range of thrust to suit all vessel types and sizes hydraulic linear drives The Type 1 and Type 2 rams combine motor pump and hydraulic cylinder as one unit referred to as an actuator Type 3 rams are supplied split into a separate motor pump unit reservoir and hydraulic cylinder connected by 1m 3ft hoses The Type 3 motor pump unit can be mounted on a vertical bulkhead Note Longer hoses for the Type 3 system are available please contact your dealer RAM T2 12V 12V dc 12V d
53. tion c offset approx 88 defined by dimensions b tiller arm gt MS OO ig Ye 5 CH Lex f ay The ram arm must be at the a a mid point of its travel d Centre line of vessel a half max rudder angle midstroke length lt The ram rose joint will allow a maximum of 9 mis alignment HER Rudder stock and steering gear assembly Page 23 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot splitting the ram drive unit Note when dealing with any hydraulic system great care must be taken to ensure that a high degree of cleanliness is observed and no dirt moisture or foreign objects are allowed to enter the system When filling or topping up the external reservoir only use a good quality ISO 10 hydraulic oil e g Q8 Dynobear 10 10cSt at 40 C It is not possible to split the following linear drives RAM TO 12V RAM T1 12V RAM T2 12V RAM T2 24V type 0 type 1 and type 2 units Comprise a combined ram pump reservoir and hydraulic cylinder These units cannot be split type 3 units Are supplied as split units connected by 1m 3ft hoses These can be supplied with quick connect couplings and pre filled hoses These units do not need to be bled Note types 3 units with longer hoses are available from your dealer Page 24 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation hydraulic drive pumps
54. wiring the connections to the pilot computer or the pilot computer electronics Page 61 www bangservice co uk 44 0 1590 689699 troubleshooting h1000 pil ot troubleshooting no drive detected fault description The pilot attempted to move the rudder but did not sense any change in rudder position or when the pilot attempted to move the rudder it moved in the wrong direction check list 1 Is the heavy duty power supply circuit breaker for the autopilot drive switched on 2 Check installation look for any slack or loose fixings in the drive system or the rudder reference as the helm is moved 3 Move the helm does the rudder indicator work if not check installation of rudder reference unit as detailed above e Disconnect clutch from pilot electronics and test operation when connected directly to power supply e Check correct power is applied 2A maximum e Check that the dip switches in the ACP computer unit are set correctly for the rudder drive unit e Check correct power is applied RAM T1 12V 12V 15A RAM T1 12V 12V 15A RAM T2 12V 12V 25A RAM T2 24V 24V 25A RAM T3 24V 24V 25A 4 _ If the fault only occurs intermittently or under heavy loads use power steer mode to move rudder while restricting movement by holding wheel Fault only occurring under these conditions could be due to e Excessive motor current e Too much slack or backlash in drive or fixing to tiller possibly due to air in hydraulic system
55. y removing the four screws holding the computer PCB into the lid of the computer unit and then carefully lifting the PCB clear Set the switches as per the table below The default setting is 9V switch 4 ON which is suitable for Size 0 1 and 2 12V rams Dip Switch Clutch Voltage Drive Size Type E A ES gt 24V Page 33 www bangservice co uk 44 0 1590 689699 description installation h1000 pilot acp dip switch location Note When reassembling the computer unit ensure that the connector in the top left hand corner of the PCB engages correctly Page 34 www bangservice co uk 44 0 1590 689699 h1000 pilot description installation h1000 and alarm connections f h1000_ h1000 x XX on O ey Na pe EV S7 oy D Red 12v Blue Ov BL PR SLV Alarm Unit 130 PK 10 Page 35 www bangservice co uk 44 0 1590 689699 description installation hand held mob and joystick 1 DR SLV BLK SLV Dn 0 0 0 o 0 0 0 ojojojoj0 BL Man Overboard Button MOB 302 00 007 Page 36 www bangservice co uk J

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