Autohelm Inboard Autopilots (ST6000 and ST7000 systems) Service ...

AutohelmAutohelm Inboard Autopilots(ST6000 and ST7000 systems)Service ManualTom Green 11/02SeaTalk Service Manual 1

Autohelm2SeaTalk Service Manual

AutohelmST7000 SystemMaster Table of Contents1. Service Procedures2. Technical InformationST7000 Control Unit (Z082)ST7000 Course Computer (Z083, Z084)ST6000 SystemST6000 Control Unit (Z124)ST6000 Course Computer (Z123)Type CR Interface Box (Z085)Rudder Reference Transducer (Z131)Fluxgate Compass Transducers (Z130)Fluxgate Compass Transducer (Z105)Rudder Reference Transducer (Z060)Masthead / Pushpit Windvane Transducers (Z080,Z087)Linear Drive Units (Z029, Z032, Z039, Z058, Z059)Rotary Drive Units (Z028, Z031, Z037)Hydraulic Drive Units (Z030, Z033, Z041, Z064,Z065, Z066, Z067, Z081)I/O Sterndrive Drive Unit (Z088)1. Service Procedures2. Technical Information1. Service Procedures2. Technical Information1. Service Procedures2. Technical Information1. Service Procedures2. Technical Information1. Service Procedures2. Technical Information1. Service Procedures2. Technical InformationService ProceduresService ProceduresService ProceduresService ProceduresService ProceduresService ProceduresService ProceduresService ProceduresService ProceduresSeaTalk Service Manual 3

AutohelmST7000 Basic System1. Service ProceduresSeaTalk Service Manual 1

AutohelmST7000 System IndexPage1. Introduction 32. System Description. 33. Operating/Calibration Instructions. 43.1 Operation 43.2 Operating Hints 83.3 Additional Information for Sailing Vessels 103.4 Calibration 123.5 Fluxgate Compass - Automatic Deviation Correction 154. Common System Problems. 165. Track Control Interfacing. 175.1 Inverted Data. 175.2 Conversion of Units. 175.3 Alarm Messages. 175.4 N.M.E.A. Input Format. 186. Special Functions. 196.1 Display of Software Version. 196.2 Permanent Watch Alarm Mode. 196.3 Display Test Mode. . 196.4 LCD Contrast Ratio Adjustment. . 197. Service Visit to a Vessel. 207.1 Onboard Diagnostics. 212SeaTalk Service Manual

Autohelm1. IntroductionThe ST7000 system section of this manual contains full system operating instructionsand service procedures for the installed autopilot. Further indepth diagnostics areavailable for each module in the relevant product sections.2. System DescriptionThe ST7000 is a modular autopilot system that can be built up to match the individualrequirements of all vessels. A range of high efficiency Rotary, Linear,Inboard/Outboard and Hydraulic drive units are available to match all types ofsteering systems.The ST7000 is SeaTalk compatible providing full data sharing with the Autohelmrange of SeaTalk Instruments.Early systems (pre March 90) were supplied with Z060, Z105 Rudder Reference andFluxgate transducers. Later systems use the Z131 and Z130 transducers.The ST7000 course computer can be used with all Seatalk compatible control unitsand will operate all of the following drive units:Z039 Linear Drive Type 1Z037 Rotary Drive Type 1Z041 Hydraulic Pump Type 1Z081 Hydraulic Pump Type 0Z088 I/O SterndriveZ029 Linear Drive Type 2 (1 2v)Z058 Linear Drive Type 2 (12v) Short StrokeZ032 Linear Drive Type 2 (24v)Z059 Linear Drive Type 2 (24v) Short StrokeZ028 Rotary Drive Type 2 (12v)Z031 Rotary Drive Type 2 (24v)Z030 Hydraulic Pump Type 2 (1 2v)Z033 Hydraulic Pump Type 2 (24v)Z064 Type CR 3L/min (1 2v) via Z085 Interface BoxZ065 Type CR 3L/min (24v) via Z085 Interface BoxZ066 Type CR 4.5L/min (12v) via Z085 Interface BoxZ067 Type CR 4.5L/min (24v) via Z085 Interface BoxSeaTalk Service Manual 3

Autohelm3. Operating/Calibration instructions3.1 OperationAutoPush to engage automaticsteering and maintaincurrent heading.Automatic HeadingORPush and hold down for 1second to return toprevious automaticheading. (Display returns toAuto after 10 seconds).Previous Automatic HeadingCourse Changes (—1, +1, —10, +10)Push to alter course to port(—) and starboard (+) inincrements of 1 and 10degrees.New Automatic HeadingStandbyPush to disengage theautopilot for manualsteering. (The previousautomatic heading ismemorised).Current HeadingTrack (see operating hints)Push to select track controlfrom Auto.Push again to return toautomatic steering.Automatic HeadingORPush and hold down for 1second to select previoustrack control heading fromAuto or Track.(Display returns to Track after 10 seconds).4SeaTalk Service Manual

AutohelmResponse• Response Level Adjustment (see Operating Hints) Response LevelPush to increase ( ▲ ) ordecrease ( ▼ ) responselevel. To display responselevel without changing itpush both Response keystogether briefly.• Rudder Gain Adjustment (see Operating Hints) Rudder Gain LevelPush and hold down for 1second both Response keystogether to display ruddergain level.Within 10 seconds pushonce to increase ( ▲ ) ordecrease (▼) rudder gain.Rudder Gain Level(Response and Rudder levels are displayed for 10 seconds only)IlluminationPush and hold down Displayfor 1 second to switch onillumination.Within 10 seconds pushDisplay to select illuminationlevel.Illumination Level3 =High2 =Medium1 =LowOFF =Off(Illumination level is displayed for 10 seconds only)SeaTalk Service Manual 5

AutohelmDisplay Key SequenceWatch Alarm (not available in Standby)• To select Watch alarm push Displayrepeatedly until Watch appears.• Cross Track Error*◄ or ► indicates direction to steer• Bearing to Waypoint*The 4 minute timer is now running:—After 3 minutes ‘Watch’ flashes on allcontrol units.—After 4 minutes the alarm sounds on allcontrol units.• Push Auto at any time to reset the timerto 4 minutes and silence the alarm.• To cancel the Watch alarm at any timepush Display.• Distance to Waypoint*• Watch Alarm (not available in Standby)*Only displayed when waypoint informationis transmitted to the control unit by a RadioNavigation System.6SeaTalk Service Manual

Autohelm3.2 Operating HintsResponse Level AdjustmentThe ST7000 has three response levelswhich enable tighter course keeping to beachieved in certain cases:-Level 1— Automatic Sea State ControlLevel 2— Automatic Sea State InhibitLevel 3— Automatic Sea State Inhibit andcounter rudder.When the autopilot is switched on, theresponse level is set to 1. This provides thebest compromise between powerconsumption and course keeping accuracyand is suitable for nearly all situations.Increasing Response level provides tightercourse keeping at the expense of increasedpower consumption and general wear andtear. It is advisable to use the minimumresponse level necessary to achieve thedesired course keeping accuracy. On largerpower vessels level 3 can improve slowspeed steering where the natural yawdamping of the vessel is reduced.Note: Level 3 is not recommended for useat planing speeds or in rough seas.+TrackTo make full use of Track control thefollowing simple points should be observed:-• Always steer the vessel to within 0.1n.m.of track and bring the heading to within 5° ofthe bearing to the next waypoint beforeselecting Track.• Always check that there are nonavigational hazards either side of theintended track.• Always maintain an accurate log withregular plots to verify the computed positionread from the Radio Navigation Receiver.• Maintain a proper lookout at all times.Automatic TrimIf Automatic Trim has been selected duringcalibration the 5T7000 will correct for trimchanges. This correction can take up tothree minutes to apply the rudder offsetnecessary to restore the set automaticheading. Large course changes whichchange the apparent wind direction canproduce large trim changes. In these casesthe autopilot will not immediately8 SeaTalk Service Manualassume the new automatic heading, andonly settle onto course when the AutomaticTrim has been fully established.It is recommended the following procedureis adopted for large course changes.• Note required new heading.• Select Standby and steer manually.• Bring vessel onto new heading.• Select Auto and let vessel settle ontocourse.• Bring to final course with 1° increments.It is sound seamanship to make majorcourse changes only whilst steeringmanually. In this way any obstructions orother vessels may be cleared properly anddue account taken of the changed wind andsea conditions on the new heading prior toengaging the autopilot.Rudder Gain AdjustmentThe rudder gain level selected during initialsea trials will normally provide excellentsteering performance over a wide range ofconditions. However, it may be noticed thatthe autopilot tends to be a little less stableon northerly headings in the higher latitudesof the northern hemisphere (and converselysoutherly headings in the southernhemisphere). This is caused by theincreasing angle of dip of the earth’smagnetic field at higher latitudes, which hasthe effect of amplifying rudder response onnortherly headings. The tendency towardsnortherly heading instability is usually moreobvious in higher speed craft and when itoccurs can be corrected by reducing therudder control setting. At speeds in excessof 30 knots, a reduction of two levels canoften be required on headings between315° and 045° (northern hemisphere) or135° and 230° (southern hemisphere).CAUTIONOn planing vessels improved coursekeeping at displacement speeds cansometimes be achieved by increasing therudder gain level. If this is done, it must bedecreased again before opening the throttleas oversteer can be extremely violent atplaning speeds.

AutohelmUnsatisfactory Steering PerformanceIf the 5T7000 has been installed and set upin accordance with the instructions in theInstallation Manual it will provide excellentsteering performance over a wide range ofconditions.If performance drops but the autopilot is stillworking correctly, the following simplechecks should find the fault:-• Has a magnetic influence beenintroduced near the fluxgate compass? i.e.anchor, chain, radio equipment,loudspeaker, tools, generator etc. Checkthat the autopilot compass heading stillcorresponds with the steering compass.• Are all fuses intact, circuit breakersengaged?• Are all screw connections tight and freeof corrosion.• If the autopilot fails to hold course checkthe Rudder Gain level. Has it been changedfrom the initial sea trials level (check inInstallation Manual)?• If the vessel wanders check that theRudder Reference Transducer linkage issecure with no free play.Hydraulic Drive Units only:-• Check that all unions are tight and bleedsystem to remove air.Failure to DisengageThe mechanical drive actuators of theST7000 are designed to ‘Fail Safe’ — Whenpower is disconnected the drive unit willdisengage leaving the steering system freefor manual control.When Standby is selected the actuator willDisengage leaving the steering free.It is remotely possible that a fault coulddevelop which could cause the actuator toremain engaged even when Standby isselected. If this happens:-• DISCONNECT THE MAIN CIRCUITBREAKER TO THE AUTOPILOT — THESTEERING WILL IMMEDIATELY BE FREE.or• IN AN EMERGENCY THE ACTUATORCLUTCH CAN NORMALLY BEOVERRIDDEN BY TURNING THESTEERING WHEEL HARD.It is emphasised that this fault is extremelyunlikely and can be immediately correctedas described.If preferred a separate Override switch canbe fitted close to the steering position whichwill break the actuator clutch drive forEmergency Use.SafetyPassage making under autopilot is avery pleasant experience which can leadto the temptation of relaxing permanentwatch. This must always be avoided nomatter how clear the sea may appear tobe.It is the responsibility of the skipper toensure the safety of his vessel at alltimes by careful navigation and that allcrew members are familiar with theprocedures required to engage anddisengage the autopilot.When searoom is restricted, a crewmember must be close to a control unitat all times if under Autopilot control.On Power craft permanent watch shouldbe maintained at the steering stationwhen at speed with the Autopilotengaged.SeaTalk Service Manual 9

Autohelm3.3 Additional Information for Sailing VesselsAutotackThe ST7000 has a built in Autotack functionwhich will turn the vessel through 100°. Thisoperates in both compass and vane modesas follows:-VanePush +1 and -1 -10 keystogether to initiate a tackturning to Starboard.Push -1 and —10 keystogether to initiate a tackturning to Port.Note: It is important that the rudder angletransducer is accurately aligned as theAutotack function mirrors standing helm andany offset will change the initial tack angle.Wind TrimWind Trim allows the autopilot to besupervised by apparent wind direction. Thewind direction is read either:-—From the SeaTalk bus (requires AutohelmST50 wind).ORPush both red keys togetherto select Wind Trim andmaintain the currentapparent wind angle.—Directly from a Masthead Transducer(Z080).OR— From an NMEA 0183 input on thecontrol unit.Automatic HeadingPush and hold down for 1second both red keystogether to return to theprevious apparent windangle.Previous Automatic Heading10SeaTalk Service Manual

AutohelmWind Change AlarmWind Trim uses the fluxgate compass asthe primary heading reference andautomatically adjusts the compass headingto maintain the original apparent wind angle.If changes in apparent wind angle adjust theoriginal automatic heading by more than 15°the wind change alarm will sound.Using Wind TrimIt is important to understand that “WindTrim” prevents over-reaction to gusts orsudden wind shifts. One minute is requiredto change the heading in response to apermanent change in apparent wind angle.Do not attempt to override the automaticsequence with the course change buttons.In gusty conditions sail a few degrees offthe wind and pay frequent attention to sailtrim and helm balance using the rudderangle indication.Performance will normally be improved byreefing headsail and mainsail a little earlyrather than too late.—The alarm is silenced by pushing both redkeys together briefly.Display of Wind AngleIf the wind angle information is suppliedusing the NMEA 0183 input or SeaTalk bus,the apparent wind angle and tack sense (P& S) is added to the display menu andaccessed via the Display button.• Apparent Wind AngleSeaTalk Service Manual 11

Autohelm3.4 CalibrationRecommended SettingsAs supplied the ST7000 can be switched onand tested safely without any adjustments tothe factory calibration settings.The table below lists the suggested settingsfor sailing and power displacement andplaning power vessels. These will providegood performance for initial sea trials and canbe fine tuned later to optimise performance.Vessel TypeDisplacement PlaningFactory preset Set toRudder Gain5 2(level)Rate Gain2 1(level)Rudder Angle Limit 30 30(degrees)Turn Rate Limit20 5(degrees/sec)Cruise Speed8 25(knots)Off Course Alarm 20 20(degrees)Trim Level 1 1Selecting and Exiting from CalibrationModeTo select calibration mode:-• Push Standby.• Push and hold down for 2 seconds,Track and Display together.• Repeat push and hold down for 2seconds, Track and Display together toenter calibration mode.To exit calibration mode at any point.a) Saving any changes made:-• Push and hold down for 2 seconds,Track and Display together.Autopilot Drive Unit TypeMechanical HydraulicFactory preset Set toDrive Type 3 4Rudder PositionDeadband (level)See 3.71 1b) Ignoring any changes made:• Push Standby.12SeaTalk Service Manual

AutohelmAdjusting CalibrationIn calibration mode, the display button isused to scroll through the menu. Thedisplayed value is adjusted using theResponse buttons (hold button down forfast scroll).• Rudder Angle Limit, 15 to 40 (see 3.6).• Rate of Turn Limit, 2 to 20°/sec.• Rudder Gain, levels 1 to 9, (see 5.5)• Cruise Speed, for Track modeoperation, 4 to 60 knots.• Rate Gain, levels 1 to 9, (see 5.6)(Counter Rudder).SeaTalk Service Manual 13

Autohelm• Off-Course Alarm, 15 to 40° angle.• Manual Steering Lever Type.1 = Proportional (Follow up)2 = Bang Bang (Drive left, Drive right)• Automatic Trim, (see 5.4).• Autopilot Drive Unit Type.1 = on0 = off1 = Future Use2 = Future Use3 = Mechanical4 = Hydraulic• Remote Control Identifier. (ForFuture Use).• Rudder Position Deadband (levels 1 to 9),(See 3.7).14SeaTalk Service Manual

Autohelm3. 5 Automatic Deviation CorrectionThe ST7000 will correct the fluxgate compass for any deviating magnetic fields. Thisshould be carried out in calm conditions preferably in flat water.• To select compass adjust Push and hold Standby for 1 second.• Keeping boat speed below 2 knots, turn the vessel slowly so that it takes at least3 minutes to complete 360°. Keep turning until the display changes to show theamount of deviation the autopilot has corrected:-Note: lf the amount exceeds 15°, it is recommended the fluxgate should be re-sited.• Use the course change buttons to adjust the displayed heading until it agrees withthe steering compass or a known transit bearing.Note: 000° is always followed by OFF. This will suppress the display of compass andautomatic headings on the control unit.• To exit compass adjust and store the compass settings push and hold Standby for1 second.• To exit compass adjust without saving any new settings push Standbymomentarily.SeaTalk Service Manual 15

Autohelm4. Common System ProblemsProblem Cause. Solution.System displays ‘Manual’mode instead of ‘Standby’on power up.Early systems had poor colourdefinition on terminal boards.Blue and Green connectionsto the Fluxgate are reversed.Reverse Blue and Greenconnections on Fluxgate.System will not pick upN.M.E.A. data from asuitable receiver.System displays ST 7000for 2 sec’s followed by ‘NOLINK’.Early systems withsoftware issues prior to66E (Z083/084) and 66C(Z082) were not fitted withNav software.Seatalk Bus non operational.Replace software in bothCourse Computer andControl unit with latestversions if pre 66E or 65C(Both software issues caneasily be checked bypressing +10 and -10 degreecourse change keys togetherfor 2 seconds.Cabling error betweencontrol units and CourseComputer.System displays ‘GYRO’mode instead of ‘STANDBY'on power up.Wind Anemometer connectedto pilot.Remove yellow connectionfrom AUX 1.System displays maximumrudder angle on power upregardless of rudderposition.System displays ‘ST7000’ or‘STANDBY’ when Auto isengaged.Early systems had poor colourdefinition on terminal boards.Blue and green connectionsto the rudder reference arereversed.Inrush currents on the poweramplifier reset either theControl unit or the CourseComputer Microprocessor.Reverse Blue and Greenconnections on rudderreference.Add C6 (100uF capacitor) tothe power amplifier PCB.Systems from S/N 890040 onhave this mod incorporated.16SeaTalk Service Manual

Autohelm5. Track Control interfacing.In most cases interfacing the ST7000 to either a GPS, Decca, Loran or SatelliteNavigation system is a simple and straight forward task, so long as the requirementsset out in section 6 of the installation manual are met. There are however a fewexceptions:5.1 Inverted Data.Some receivers, notably some of the Furuno range and early Navstar models,transmit data in an inverted format with respect to 5V. This is easily seen as the dataline will idle high with respect to 0V in between data transmissions. In these casesthe NMEA cable on the rear of the control unit must be wired with the red wireconnected to 5V, (this is normally available on the receiver terminal block), and theblue wire connected to the data line.5.2 Conversion of Units.The Control Unit will convert all units of distance to Nautical Miles. Therefore, anyreceivers displaying Cross Track Error or Distance To Waypoint in either Kilometresof Statute miles etc will have their data displayed on the Control Unit in NauticalMiles.5.3 Alarm Messages.Track mode has 3 alarm messages:-1. No Data If a standard N.M.E.A sentence is not received by the ST7000.2. Data Error The ST7000 has recognised the incoming data as N.M.E.A buthas detected an invalid flag. This is normally due to poor signalstrength at the receiver.3. Large XTE Cross Track Error greater than O.3NM.Errors 1 and 2 can provide valuable information as to where an installation problemmight lie. The ‘NO DATA’ message indicates the ST7000 is not receiving N.M.E.Adata due to either the receiver output not being enabled or more likely a wiring errorbetween the receiver and the pilot. The ‘DATA ERROR’ message indicates theST7000 is receiving data recognised as N.M.E.A but has an invalid flag set. This isnormally due to the receiver having a low signal strength or a high noise figure.SeaTalk Service Manual 17

Autohelm5.4 Autohelm 7000 N.M.E.A 0183 Data input Format.The 7000 must receive Cross Track Error data at least once every 30 seconds.If a display of Waypoint bearing and distance is required then this information mustbe received at least once every 30 seconds. All N.M.E.A data is read into a bufferthus enabling the 7000 to cope with delays between characters and delays betweensentences. All Talker Identifier characters, i.e. RA, DE, LC etc. are ignored allowinginterface with any type of equipment so long as the sentence type is one of thefollowing:-TrackControlBearing toWaypointDistance toWaypointApparent Wind Speed &DirectionXTE APB WDR VWRXTR BPI WDCAPA BWR BPIAPB BWC BWRRMB BER BWCBECRMBBERBECRMBApparent Wind Speed and Angle can be received from any external equipmenttransmitting the N.M.E.A. VWR header. The ST7000 will only display apparent winddirection but will convert and retransmit both apparent wind speed and apparent winddirection on the Seatalk bus. This information can then be displayed on an ST50 windinstrument acting as a repeater.18SeaTalk Service Manual

Autohelm6. Special functions.6.1 Display of Software VersionIt is possible to display the version number of both Course Computer and ControlUnit software installed in a particular system. This is achieved by pressing both the+10 and -10 keys together for 2 seconds and releasing. The display will show theControl Unit Version (65 followed by Issue Level) for 10 seconds, followed by CourseComputer Version (66 followed by Issue Level). The pilot must be in standby mode atthe time. Each version is displayed for 10 seconds before the pilot reverts to standby.A software history for each product is shown in the relevant Service Section.6.2 Permanent Watch Alarm Mode.The ST7000 autopilot can be set up in a permanent watch alarm mode, as requiredby the Sea Fish Industry Authority (S.F.l.A).It must be stressed that the selection of this mode is permanent and can only bereversed by returning the Course Computer to Nautech.Permanent Watch Alarm is achieved by first entering the calibration menu. Once incalibration, regardless of display message, press the Auto, Standby, and Track keystogether for 1 second before releasing. The display will now show ‘SELECT WATCH’.The user now has 10 seconds to select permanent watch alarm mode by againpressing Auto, Standby and Track together for 1 second. The display will then show‘WATCH ON’ for 10 seconds before reverting back to ‘CAL’. A normal exit fromcalibration mode must now be executed.6.3 Display Test Mode.All display segments on the control unit can be switched on by pressing the +10, -10,Standby and Display keys together. This mode can only be accessed after the unithas been powered up with the yellow SeaTalk data wire open circuit. (This is bestdisconnected in the Course Computer Connector box (Bus 1 and Bus 2).)6.4 LCD Contrast Ratio Adjustment.In certain circumstances, it may be necessary to adjust the contrast ratio of the Z082Control Unit LCD. This procedure is detailed in Section 4 of the ZO82 Control UnitSection.SeaTalk Service Manual 19

Autohelm7. Service visit to a vessel.When a service visit to a vessel is made the most common fault en-countered is likelyto be poor connections or inadequate power supplies. These should be thoroughlychecked before the Service visit diagnostic procedure is carried out.When trying to locate a fault it should be remembered that most failures will occur inthe Course Computer with the Control Units as the next most likely.It should be noted that the calibration variables and auto deviation correction willrequire re-setting if the Course Computer, Course Computer Software or its PCB areexchanged. A procedure for carrying out this operation is given in section 3. Alwaysnote the Course Computer calibration settings before removing from the vessel.20SeaTalk Service Manual

Autohelm7.1 Service Visit - Diagnostic ProcedureOn arrival check for bad connections (corroded connector pins, loose connectors etc)and for inadequate power supplies. If the system still exhibits a fault, then use thediagnostic procedure outlined below. Once the faulty module has been detected referto the relevant Product Section for detailed service information.SeaTalk Service Manual 21

AutohelmZ082 Control Unit1. Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Dismantling 33. Re-assembly 34. Display Contrast Adjustment 45. Functional Test 76. Product History 97. Software History 98. Spares Numbers 9IllustrationsFig. 1. Z082 Control Unit General Assembly 5Fig. 2. LCD/Diffuser Assembly 62SeaTalk Service Manual

Autohelm1. DescriptionThe Z082 Control Unit is SeaTalk compatible and consists of a single PCB built usingsurface mount technology. It can be used with both 12V and 24V SeaTalk CourseComputers. The unit can also be functionally tested without the use of specialequipment using the procedure outlined in figure 3.2. Dismantling (ref fig 1.)Note: To prevent damage to the printed face of the unit all work should be carried outon a flat surface covered in foam rubber. A conductive surface will prove beneficial inhelping to prevent dust accumulation caused by static on the workbench.1. Unscrew and remove the 6 case securing screws from the rear cover. Push eachcable loom assembly back through its grommet so as to obtain working clearance tothe PCB (fig 1).Note: Failure to push the cables back to ease removal may damage the cable to PCBassembly. If cables are very tight in grommets apply a small smear of silicon greaseto outer sheath, (grease can be wiped off after reassembly).If removing the PCB assembly, it will be necessary to de-solder the cables from thePCB. Great care should be exercised when de-soldering so as not to damage thepads on the PCB.2. Unscrew and remove the 10 screws which secure the PCB to the facia.Note: Do not at this stage remove the screws which secure the LCD assembly to thePCB. (fig 2.).3. Before removing the LCD ensure that lint free and preferably anti static finger cotsare worn to prevent the LCD or elastomers getting dirty or greasy.4. Unscrew and remove the 8 LCD housing retaining screws, (fig 2.). Be careful tohold the LCD surround, LCD, and diffuser when dismantling. Lift away from the PCBand store carefully.3. ReassemblyReassembly is a straight reversal of the above procedure but note the followingpoints:1. Note the correct orientation of the various looms and core colours to the PCB pads(fig 1).2. Ensure the LCD is correctly orientated relative to the PCB (fig 2).3. Ensure the diffuser is correctly orientated relative to the LCD and PCB (fig 2).4. Always ensure the board is tightened down sequentially to ensure the load isevenly spread.SeaTalk Service Manual 3

Autohelm5. When finally refitting the cover to the facia ensure that the cover is in the correctposition relative to the cables and pull the cables back through the grommets as thecover is lowered onto the facia. Wipe off any excess grease from the cable sheaths.6. Use only hand screwdrivers for reassembly to ensure screws are not overtightened and elastomers are compressed uniformly. Rotate screws anticlockwise tolocate in the thread before tightening.7. Re-check for full function after reassembly to check the LCD has not beendamaged or looms incorrectly soldered.4. Display Contrast AdjustmentThe Display Contrast on the Z082 Control Unit can be manually adjusted to suitinstallations where the LCD is normally viewed from significantly above or below, orwhen a replacement LCD with different drive characteristics has been fitted.1. Remove power from the unit.2. Unscrew the mounting thumb nuts and ease the Control unit forward from itsmounting position.3. Unscrew and remove the 6 case screws from the rear cover. Push each cableloom back through its grommet so as to obtain working clearance to the PCB (fig 1).Note: If cables are tight in grommets then apply a small smear of grease to the outersheath, (grease can be wiped off after reassembly).4. Re-connect power.5. View Control unit from normal operating angle.6. Adjust vrl, (see figure 1 for location) to obtain optimum display legibility.7. Refit the cover to the facia ensuring correct positioning relative to the cables. Pullthe cables back through the grommets as the cover approaches the facia.8. Secure Control unit in its original position.Note: Use only hand screw drivers to reassemble to ensure screws are not overtightened.4SeaTalk Service Manual

AutohelmControl Unit General Assembly (Z082)Fig. 1.SeaTalk Service Manual 5

AutohelmLCD Display Assembly6SeaTalk Service ManualFig. 2.

Autohelm5. Functional TestSeaTalk Service Manual 7


Autohelm6. Product History (Z082)Change Serial Number CommentsProduction Start 290001Track Compatibility 690075When used with a Track CompatibleCourse ComputerWhite Back Light diffuserintroduction890007Protective Cover suppliedwith unit100001SeaTalk Cable suppliedwith unit3000567. Software History (Z082)Version Change Course Computer CompatibilityBInitial releaseAll versions(S/No. 290001)CTrack function added, Rudder Angledisplay updates at a faster rate.(S/No. 690075)All versions but must be used with atrack compatible Course Computer ifthe track function is required.8. Spares Numbers - Control Unit (Z082)Item Catalogue No CommentsDouble Skin mounting kit Q003Allows Control Unit to be mountedon up to 4" thick bulkheadsPCB Assembly Q004 No LCD includedLCDQ026White Backlight Diffuser Q023Protective CoverD122SeaTalk Service Manual 9


Autohelm2. Technical InformationContentsPage1. Circuit description 21.1 Power Supply 21.2 Microprocessor and Program Memory 21.3 LCD and Display Driver 21.4 Negative Rail Generator 21.5 N.M.E.A. Interface 21.6 Seatalk Bus Transmit and Receive 21.7 Keypad Operation 31.8 Buzzer Operation 31.9 Illumination Drive 3IllustrationsFig.1. Circuit Diagram 5Fig.2. PCB Assembly/Parts List 7SeaTalk Service Manual 1

Autohelm1. Control Unit PCB Circuit DescriptionCircuit Diagram Fig. 1.PCB Assembly/Parts List Fig. 2.1.1 Power SupplyIncoming power is routed to the PCB via PL1 and SKT1. D4 and D20 protect againstreverse connection of the supply. IC1 is a 5V regulator and can also reset themicroprocessor, via TR1, should the supply voltage fall below approximately 6V.1.2. Microprocessor and Program MemorylC6 is an Intel 80C32 microprocessor. It can access up to 32k bytes of programmemory (lC5) via the latch lC4. A clock signal for the microprocessor is provided byan 1 1MHz ceramic resonator (XL1), and associated capacitors C7 and C8.Capacitors C6, C9 and C10 provide decoupling.1.3. LCD and Display DriverThe LCD is a Nautech custom part. The display is driven by a Hitachi LCD driver(IC3) deriving its drive voltages from resistor chain R24-R27 and VR1.Communication to the microprocessor is via a 4 bit parallel bus (DB4 to DB7) and thethree control lines E, R/W and RS. Capacitors C18 and C22 provide decoupling andresistor R44 the clock signal for lC3.1.4. Negative Rail GeneratorA negative voltage rail is required by the LCD display and is generated by a switchingregulator formed by TR11, D10 and D21. A 4.8KHz waveform is generated from themicroprocessor P3.4 (pin no. 16). This drives a charge pump, via transistorTR11,pumping charge from C19 via D1O and C20. The negative rail is then stabilised byD21 and R60.1.5. N.M.E.A InterfaceNMEA data is fed to the control unit via PL2 and isolated from the rest of the circuitusing the opto-isolator (lC7). Diode D1 provides input reverse connection protectionand resistor R35 is tuned to give the desired bandwidth of operation. The output fromIC7 is connected to the microprocessor Port P3.2 (pin 14). Capacitor C21 providesdecoupling.1.6. SeaTalk Bus Transmit and ReceiveSeaTalk transmit and receive circuitry consists of TR5, 6, 7, 8, 9, 14 and 15 and theirassociated components. Data transmission is at 4800 band with a low start bit andline idling high. TR7 and TR8 provide high and low drive respectively, whilst TR14and R57 give overload protection to TR8 in the event of misconnection. TR5 and TR6allow the microprocessor to monitor its own transmissions and also to receive datafrom other units on the bus.2SeaTalk Service Manual

Autohelm1.7. Keypad OperationThe 10 button key pad is configured in a 4*3 matrix and connected to themicroprocessor P1.0 and P1.6 (pins 2 to 8). Each key is diode isolated to enablemultiple key presses to be decoded.1.8. Buzzer OperationTR2 and TR3 are configured as an astable multivibrator with a nominal frequency of2.7KHz. TR4 is used to switch the buzzer with TR13 acting as an invertor to turn thebuzzer off during a micro-processor reset.1.9. Illumination DriveTR10, 12 and 16 provide a constant current drive for lamps LP1, LP2, LP3 and LP4.The current is set by resistors R56 and R62. TR12 is an inverting buffer to turn off thelights during a microprocessor reset. Illumination levels are given by pulse widthmodulation of drive line P3.3 (pin 15 of lC6).SeaTalk Service Manual 3


Autohelm-Fig. 1. Z082 Control Unit Circuit Diagram ISS CSeaTalk Service Manual 5


AutohelmNOTES1. ALL SURFACE MOUNT CAPACITORS AND RESISTORS TO HAVE NICKEL BARRIERSOLDER PLATED TERMINATIONS2. ITEM 4 (15036) TO BE SANDWICHED BETWEEN ITEM 5 (15039) AND PCB TOINSULATE HEATSINK FROM 5V TRACK CONNECTED TO IC 1 (PIN 2)3. ITEM 6 15085) TO LIE FLAT ON P.C.B. AS SHOWN.47 OR 1 LCD DISPLAY DRIVER KS0062 (SAMSUNG) IC346 EITHER 1 LCD DISPLAY DRIVER HD44780 (HITACHI)AND45 OR 1 TRANSISTOR BC337 NPN (TO BE ASSEMBLED WITHMAXIMUM LEAD LENGTH =4MM)44 EITHER 1 TRANSISTOR SOT89 BCX68 NPN TR16PLUS43 10 CONTACT CLICKER 00K-73470 S1, S2, S3, S4, S5, S6, S7, S8, S9, S1042 1 CHIP TRIMMER RESISTOR 1K MURATA RVG 4F03A-102VM VR141 1 OPTO ISOLATOR 6N139 LEADS TO BE FORMED FORBUTT JOINT CONNECTION (ie HPs OPTION 100)IC740 1 MICRO ROM LESS 80C32 12MHz PLCC IC639 1 HCMOS LATCH 74HC373 IC438 1 VOLTAGE REGULATOR LM2925 IC13? 1 TRANSISTOR SOT 23 BC807 PNP TR7TR1, TR2, TR3, TR4, TR5, TR6, TR8, TR9,36 14 TRANSISTOR SOT 23 BC817 NPNTR10, TR11, TR12, TR13, TR14, TR1535 5 DIODE SOT 23 BAW56 D6, D7, D8, D15, D1634 3 DIODE SOT 23 BAV99 D2, D10, D2133 1 DIODE SOT 23 BAS 16 D1232 3 DIODE SOT23 BAS19 D1, D4, D2031 2 CAPACITOR SOLID TANT. 10UF ±20% 6V3(SIZE C) C19, C2030 1 1206 CAPACITOR 1000pF ± 10% 5OV X7R C1129 2 1206 CAPACITOR 33pF ±5% 50V COG C7, C828 3 1206 CAPACITOR 22pF ±5% 50V X7R C2, C4, C527 1 1206 CAPACITOR 0.1µF ±20% 50V X7R26 1 ELECTROLYTIC CAPACITOR 100uF ±20% 6.3V MIN 5.5 MAX C325 1 1206 RESISTOR 100K 5% 0. 125W R3524 4 1206 RESISTOR 1K0 2% 0.125W R24.R25R26R2723 1 1206 RESISTOR 220R 5% 0. 125W R4222 1 1206 RESISTOR 680R 5% 0 125W R6021 1 1206 RESISTOR 10R0 1% 0.125W R5620 1 1206 RESISTOR 91K 2% 0. 125W R4419 1 1206 RESISTOR 8R2 5% 0.125W R34, R47, R57, R5918 3 1206 RESISTOR 39K 5% 0.125W R10, R11, R1917 1 1206 RESISTOR 22K 5% 0. 125W R2116 1 1206 RESISTOR 15K 5% 0. 125W R1215 9 1206 RESISTOR 12K 5% 0. 125W R1, R2, R6, R7, R9, RZ2, R23, R50, R5514 4 1206 RESISTOR 4K? 5% 0.125W R13R32R54R5813 3 1206 RESISTOR 2K2 5% 0.125W R3, R14, R2012 3 1206 RESISTOR 1K2 5% 0.125W R31, R51, R5211 2 1206 RESISTOR 470R 5% 0 . 125W R5, R810 1 1206 RESISTOR 390R 5% 0. 125W R189 1 1206 RESISTOR 13R0 1% 0.125W R628 1 BUZZER KBS-27DB~3T7 26006 1 RIVSCREW 1712-3507 (AVDEL)6 15085 1 CERAMIC RESONATOR 11MHz (CSA 11.0MT) XL15 15039 1 HEATSINK REDPOINT TV584 15036 1 TRANSISTOR MOUNTING PAD3 07164 1 28 PIN IC SOCKET2 3015-028 1 7000 CONTROL UNIT PCB DETAIL1 3010-036 10 CLICKER SEALITEMS DRG/PART N* QTY DESCRIPTIONFig. 2 . Z082 Control Unit PCB Assembly/Parts List ISS SSeaTalk Service Manual 7


AutohelmZ084 Course Computer (24V) & Z083 Course Computer(12V)1. Service ProceduresZ083 COURSE COMPUTER (12V)Z084 COURSE COMPUTER (24V)SeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Dismantling 33. Re-assembly 44. Functional Test 74.1 Bench Test (stage 1) 84.2 Bench Test (stage 2) 144.3 Bench Test (stage 3) 155. Product History 166. Software History 167. Spares Numbers 16IllustrationsFig. 1. Course Computer General Assembly 5Fig. 2. Power Amplifier General Assembly 62SeaTalk Service Manual

Autohelm3. Re-assemblyIn all cases re-assembly is a reversal of the dismantling procedures above, but note;-1. Ensure correct orientation of power amp PCB loom when reconnecting to thecomputer PCB. Ensure a loom clip is fitted to the ribbon cable connector.2. Ensure that insulating caps are all in place before sliding the power amp PCB backinto the extrusion. Ensure that the silpads are fitted between the transistors and theextrusion.3. Ensure that the correct transistor type is placed at each location. (Fig. 2).4. Ensure that transistor/PCB securing screws are not loose, but do not over tighten.4SeaTalk Service Manual

ST7000 Course Computer General Assembly Z083-12V and Z084-24VAutohelmFig. 1.SeaTalk Service Manual 5

AutohelmST7000 Course Computer (Z083, Z084) - Power Amp PCB Assembly6SeaTalk Service ManualFig. 2.

Autohelm4. Functional TestThe Course Computer can be functionally checked by using the following procedure.Pre checked equipment required;-SeaTalk Control Unit (Z082)Fluxgate Compass (Z105)Pushpit Vane Transducer (Z087)Rudder Reference Transducer (Z060)Terminal PCB (Q006)Terminal BlockMultimeterMotor for Z083 (12V) (N002)Motor for Z084 (24V) (N003)Power Supply (min rating 20A)SeaTalk Cable (D131)Procedure:a) Connect all units to course computer and terminal board PCB.b) Position the rudder reference transducer arm diametrically opposite the cablegland.c) Connect 12V (Z083), 24V (Z084) electronic and heavy duty supplies (do not switchon).d) Start at Bench Test Stage 1. The procedure will determine if the course computeris faulty or correct and in most cases will also identify the nature of the fault andcorrective action required. Some faults require further investigation and this iscovered in stage 2 and stage 3.SeaTalk Service Manual 7

Autohelm4.1 Course Computer Bench Testing (Stage 1)8SeaTalk Service Manual

AutohelmSeaTalk Service Manual 9





Autohelm4.2 Course Computer Bench Testing (Stage 2)1. Proceeding from stage 1 bench testing, remove the four screws retaining thecomputer PCB cover assembly and slide the PCB clear of the extrusion. Do notdisconnect the loom.14SeaTalk Service Manual

Autohelm4.3 Course Computer Bench Testing (Stage 3)Proceeding from stage 1 bench testing, remove 4 screws retaining the computer PCBcover assembly and slide the PCB clear of the extrusion. Do not disconnect the loom.SeaTalk Service Manual 15

Autohelm5. Product History Course Computer (Z083 & Z084)Change Serial Number CommentsProduction Start 290001Track Function Introduced 590206 Must be used in conjunction with aControl Unit capable of supporting theTrack functionCapacitor 'C6' (100µf) fitted topower amplifier board890040 Cures occasional system reset toStandby mode when initially engagingAuto after power up.6. Software History (Z083 & Z084)Version Change Control Unit Compatibility S/NoC Initial release All versions 290001DAuto Seastateproblem curedAll versions 490081EGTrack function added All versions. If Track keeping algorithm isrequired then control unit must also beTrack CompatibleTrim functionImproved590206All versions 5002567. Spares Numbers - Course Computers (Z083 & Z084)Item Catalogue No. CommentsConnector Unit terminal PCBassemblyQ006Course Computer PCBassemblyQ007Power Amplifier PCB assembly(Z083) M062 12v versionPower Amplifier PCB assembly(Z084) M063 24v versionPNP Power Transistors(2offMJ11029)NPN Power Transistors(2offMJ11028)L010L00916SeaTalk Service Manual

Autohelm2. Technical InformationContentsPage1. Circuit Description (Course Computer PCB) 21.1 Power Supplies 21 .2 Microprocessor and Program Memory 21.3 Analogue to Digital Converter 21.4 Clutch Drive 31.5 SeaTalk Bus Transmit and Receive 31.6 Fluxgate Drive 31.7E2prom 31 .8 Supply Voltage Monitor 31.9 Alarm Drive 32. Circuit Description (Power Amplifier PCB) 32.1 Voltage Regulator (24V) Systems only) 32.2 Reverse Connection Protection 32.3 Bridge Amplifier 4IllustrationsFig. 1. Course Computer PCB Circuit Diagram 5Fig. 2. Course Computer PCB Assembly/Parts List 7Fig. 3. Power Amplifier PCB Circuit Diagram (12V and 24V) 9Fig. 4. Power Amplifier PCB Assembly/Parts List (Z083 1 2V) 11Fig. 5. Power Amplifier PCB Assembly/Parts List (Z084 24V) 13Fig. 6. Terminal PCB Circuit Diagram 15Fig. 7. Terminal PCB Assembly 17SeaTalk Service Manual 1

Autohelm1. Course Computer PCB Circuit Description;-Circuit diagram Fig. 1.PCB assembly/parts list Fig. 2.1.1. Power SuppliesIncoming power is routed to the PCB via the 'D' connector plug PL1. VI providessuppression against any voltage spikes present on the incoming DC supply whilst D6protects against reverse connection of the supply. 1C 1 is a 5V regulator and canalso reset the microprocessor, via TR9, should the supply voltage fall below 6V.TR17, C19, D13, R92 and R91 form an 8V regulator to supply the windvane.1.2. Microprocessor and Program MemoryIC2 is an Intel 80C32 microprocessor. It can access up to 32k bytes of programmemory (IC7) via the latch IC6. A clock signal for the microprocessor is provided byan 11 MHz ceramic resonator (XL1) and associated capacitors C15 and C16. C14,18 and 17 provide decoupling.1.3. Analogue to Digital ConverterIC3,4,5 and 9 form a software driven analogue to digital converter. IC3 and IC9 are 8channel multiplexed analogue switches routing all analogue signals, (see tablebelow), through to IC4 which is configured as an integrator. C9 is discharged at aconstant rate triggering the comparator IC5 as it reaches a level of approximately0.53V. The output of the comparator is connected to the microprocessor thusmeasuring the discharge time which is proportional to the analogue input.Analogue Channels;-IC3 Channel 0 Reset integratorChannel 1Integrator discharge signalChannel 2Fluxgate sense AChannel 3Fluxgate sense BChannel 4 Motor Feedback 1Channel 5 Motor Feedback 2Channel 6 Windvane sense 1Channel 7 Windvane sense 2IC9 Channel 0 Alarm sense 1Channel 1 Alarm sense 2Channel 2Rudder ReferenceChannel 3Supply MonitorChannel 4Rate Gyro senseChannel 5Gyro Compass senseChannel 6JoystickChannel 7Not used2SeaTalk Service Manual

Autohelm1.4. Clutch DriveTR10, 11 and 12 switch a nominal 12V onto the actuator clutch whenever pin 15 ofthe microprocessor (IC2) is low at 0V.1.5. SeaTalk Bus Transmit and ReceiveSeaTalk transmit and receive circuitry consists of TR1, 2, 3,4, 5, 18 and 19 and theirassociated components. Data Transmission is at 4800 baud with a low start bit andline idling high. TR1 and TR2 provide high and low outputs respectively, whilst TR3and Rl give overload protection to TR2 in the event of misconnection. TR4 and TR5allow the microprocessor to monitor its own transmissions and also to receive datafrom other units on the bus.1.6. Fluxgate DriveIC2 produces a series of 8KHz pulses on pin 2 which are then fed through TR6, 7and 8 and AC coupled to the fluxgate via C3.1.7 E 2 PromIC8 is an e 2 PROM (Electrically Erasable and programmable Read Only Memory)which allows calibration values to be stored and recalled each time after power up.Data is written to the e 2 PROM on pin 3 and read back on pin 4.1.8 Supply Voltage MonitorR53 and R54 scale down the supply voltage and feed it through to the analogue todigital convertor. This enables the microprocessor to transmit a warning on theSeaTalk bus if the supply voltage drops below 11.2V (12V system) or 22.4V (24Vsystem) for 10 seconds or more.1.9. Alarm DriveThe two main warning alarms are driven via TR13, 14, 15 and 16. ComponentsR41,42, 79,80 and D7 and 8 are used to detect any tampering with the alarmconnections, as required by the SFIA.2. Power Amplifier PCB Circuit Description;-Circuit diagram 12V-figure 3Circuit diagram 24V - figure 3PCB layout 12V-figure 4PCB layout 24V-figure 5The power amplifier electronics consist of three main areas;-1. Voltage regulator 24V-12V. (Not present on 12V boards).2. Reverse connection protection.3. Current amplifier bridge.2.1. Voltage Regulator (24V systems only)TR13 and TR14 together with associated components form a 24-12V regulatorrouting 12V to the course computer board via PL1.SeaTalk Service Manual 3

Autohelm2.2. Reverse Connection ProtectionTR1 and TR2 along with RL1,2 and 3 ensure that external misconnection of Heavyduty V+, Heavy duty 0V and M1 and M2 will not damage the unit.2.3. Bridge AmplifierTR6, 7,8 and 9 form a bridge amplifier to control the actuator motor. Four modes ofoperation are possible, each selectable with a binary code on drive A and drive B.Mode 1 - Drive A and drive B both a logic 1. The motor is shorted via TR7 and TR9.This mode is used for stopping the motor quickly.Mode 2 - Drive A and drive B both at logic 0. The motor is open circuit and thereforemay run as a generator allowing measurement of motor back emf. R14 and R16 incombination with R25 and R28 on the computer PCB scale down the back emf.Mode 3 - Drive A is at logic 1. Drive B is at logic 0. The motor will rotate clockwise.Mode 4 - Drive B is at logic 1, drive A at logic 0. The motor will rotate anti-clockwise.TR4 and TR10 are interlocks, switching off TR8 and TR6 when both drives areswitched high in mode 1. C3 and C20 suppress motor brush noise.4SeaTalk Service Manual

AutohelmFig. 1. ST7000 (Z083 and Z084) Course Computer Circuit Diagram ISS BSeaTalk Service Manual 5

Autohelm51 91063K9 1 WCR 1206 3K9 5X . 125W R23 52 910333K 2 WCR 1206 33K 1% .I25W R30.4350 940093061 1 EEPROM 16 x 16 M9306M 1 (SURFACE MOUNT) IC8 53 91036K8 2 WCR 1206 6K8 1% .125W R37 3849 54 910310K 3 WCR 1206 10K 1% .125W R39.40.4948 940374373 1 LATCH 74HC373 IC6 55 910668R 1 WCR 1206 68R 5X .125W R9247 9400CA3130 2 F.E.T. OP. AMP CA3130M (SURFACE MOUNT) IC4, 5 56 930522N 1 CAPACITOR 1206 22nF ±5% X7R 50V C546 94024051 2 ANALOGUE SWITCH CD74HC405 1M1SURFACE MOUNT) IC3, 9 57 9203BZX9V1 1 ZENER DIODE SOT23 BZX 84C9V1 D1345 940680C32 1 MICRO ROM LESS 8032 12MHz PLCC NMOSOR 80C32 12MHz PLCC CMOS44 04049 1 5v REGULATOR LM2925 IC143 05035 1 TRANSISTOR PNP BDW94B TR1242 9500BC817 14 TRANSISTOR SOT23 NPN BC817 TR2, 3, 4, 5, 6, 7, 9, 10, 11, 13,14,17, 18, 1941 9500BC807 4 TRANSISTOR SOT23 PNP BC807 TR1, 8, 15, 1640 03067 1 CAPACITOR TANTALUM 100uF ±20% 6V3 2.5 PITCH C639 93102U2 1 CAPACITOR CASE A 2.2uF ±20X 6V3MIN C338 9307470P 1 CAPACITOR 1206 470pF ±201 50v C2037 931233P 2 CAPACITOR 1206 33pF ±5$ 50v C15, 1636 93070U1 12 CAPACITOR 1206 0.1µF ±20* 50v C2, 4, 7, 8, 10, 11, 12, 13, 14, 17,18, 1935 93161000P 2 CAPACITOR 1206 1000pF ±2% COG 50v C1, C93433 02031 1 DIODE MR751 (MOTOROLA) D632 9200BAS19 1 DIODE SOT23 BAS19 D1231 9200BAS16 9 DIODE SOT23 BAS16 D2, 3, 4, 5, 7, 8, 9, 10, 113029 91063R3 2 WCR 1206 3R3 5% .125W R87, 8828 9106470K 1 WCR 1206 470K 5% .125W R6827 910382R 1 WCR 1206 82R 5% .125W R6226 91035K6 3 WCR 1206 5K6 5% .125W R53, 59, 9025 910368K 13 WCR 1206 68K 5% .125W R33, 34, 35, 36, 41, 42, 44, 45, 46,47, 48, 63, 8924 9103270R 3 WCR 1206 270R 5% .125W R28, 29, 6523 91031K 6 WCR 1206 1K 5% .125W R26, 27, 31, 32, 54, 642221 91061K5 3 WCR 1206 1K5 5% .125W R16, 18, 9120 91034K7 2 WCR 1206 4K7 5% .125W R73, 7419 91064K7 3 WCR 1206 4K7 5% .125W R12, 75, 7618 910615K 1 WCR 1206 15K 5% .125W R1017 910610K 13 WCR 1206 10K 5% .125W16 910622K 1 WCR 1206 22K 5% .125W R815 91062K2 6 WCR 1206 2K2 5% .125W R6, 7, 83, 84, 85, 8614 91061K8 2 WCR 1206 1K8 5% .125W R77, 7813 91031K2 5 WCR 1206 1K2 5% .125W R4, 5, 17, 19, 6112 91061K211 9106390R 1 WCR 1206 390R 5% .125W R310 910639K 3 WCR 1206 39K 5% .125W R2, 11, 139 91068R2 5 WCR 1206 8R2 5% .125W R1, 20, 21. (691,70,71, (72) SEE NOTE8 01051 1 VAR1STOR ZNR TYPE D ERZC07DK270 V17 26005 2 RIVSCREW (1712-350916 15085 1 CERAMIC RESONATOR 11MHz CERALOCK CSA 11.OMT XL15 15033 2 HEATSINK4 07164 1 1C SOCKET (28 PIN) SKT13 07155 1 16 WAY HEADER PL22 07118 1 'D 'CONNECTOR 25 WAY PL11 3015-030 1 7000 COMPUTER P.C.B DETAILITEMS DR'G/PART N* QTY DESCRIPTIONIC2 58 15036 1 TRANSISTOR MOUNTING PADFig. 2. Z083 and Z084 Course Computer PCB Assembly/Parts List ISS GSeaTalk Service Manual 7


AutohelmZ083 Power Amplifier Circuit Diagram 12VZ084 Power Amplifier Circuit Diagram 24VFig. 3.SeaTalk Service Manual 9


Autohelm21 03031 f CAPACITOR ELECTROLYTIC 100uF +80% -20% 25VMIN C620 01083 1 RESISTOR C’FILM 3K9 .25W ±5% R319 15057 3 RELAY T90.30A RL1, 2, 318 13024 1 LINK LK117 05019 4 TRANSISTOR PNP BC 327 TR4, 5, 10, 1116 05018 4 TRANSISTORS BC 337 TR1, 2, 3, 1215 03036 2 CAPACITOR TANTALUM 1µF ±20% 25vmin C3, 2014 03023 1 CAPACITOR ELECTROLYTIC 1000µF +80% -20% 60vmin C513 03020 2 CAPACITOR CERAMIC 0.01µF ±20% 25vmin C2, 4\? 02004 4 DIODE IN 4148 D2, 3, 5, 611 02002 1 DIODE IN 4818 D810 01158 4 RESISTOR CTILM 1K5 .25W ±5% R7, 9, 20, 229 01157 2 RESISTOR WIREWOUND 82R 2.5W ±5% R12. 188 01102 ? RESISTOR CTILM IK .25W ±1% R14. 167 01061 3 RESISTOR CTILM 6K8 .25W ±5% R5, 6, 246 01055 t RESISTOR CTILM 270R .5W ±5% R155 01045 4 RESISTOR CTILM 220R .25W ±5% R11, 13, 17, 194 01032 4 RESISTOR CTILM ZK2 .25W ±5 R8, 10, 21, 233 01003 1 RESISTOR CTILM IK .25W ±5% R42 4021-024 1 LOOM S'ASSY1 4021-023 1 POWER AMP. S'ASSY 1st STAGEITEMS DR'G/PART N* Q'T'Y DESCRIPTIONFig. 4. Power Amplifier PCB Assembly/Parts List (Z083) ISS BSeaTalk Service Manual 11


Autohelm24 15057 3 RELAY T90 30A RL1, 2, 323 05019 4 TRANSISTOR PNP BC 327 T4, 5, 10, 1122 05018 5 TRANSISTOR NPN BC 337 T1, 2, 3, 12, 1321 03036 2 CAPACITOR TANTALUM 1µF±20% 25vmin C3, 2020 03031 CAPACITOR ELECTROLYTIC 100% 525vmin C619 03023 CAPACITOR ELECTROLYTIC 1000µF 60vmin C518 03020 CAPACITOR CERAMIC 0.01µF ±20% 25vmin C2.417 03007 CAPACITOR CERAMIC 0.1µF ±20% 25vmin C116 02025 ZENER DIODE BZX 6 1C 15V D915 02004 DIODE IN 4148 D2, 3, 5, 614 02002 DIODE IN 4818 D813 01162 RESISTOR WIREWOUND 330R 2.5W+5% R12, 1812 01140 RESISTOR C'FILM 120R 2.5W ±10% R211 01139 RESISTOR C'FILM 680R .5W ±5% R2610 0112? 2 RESISTOR C'FILM 6K8 .25W +1% R14, 169 01083 5 RESISTOR C'FILM 3K9 .25W ±5% R3, 7, 9, 20, 228 01061 3 RESISTOR C'FILM 6K8 .25W ±5% R5, 6, 247 01055 1 RESISTOR C'FILM 270R .5W ±5% R156 01045 4 RESISTOR C'FILM 220R .25W ±5% R11, 13, 17, 195 01031 i RESISTOR C'FILM 560R .25W ±5% R14 L01006 4 RESISTOR C'FILM 5K6 .25W ±5% R8, 10, 21, 233 01003 2 RESISTOR C'FILM 1K .25W ±5% R4, 252 4021-028 1 POWER AMP. S'ASSY 1st STAGE1 LJ402 1-024 1 LOOM S'ASSYITEMS DR'G/PART Ne QTY DESCRIPTIONFig. 5. Power Amplifier PCB Assembly/Parts List (Z084) ISS BSeaTalk Service Manual 13


AutohelmColour codeSc WhiteR RedG GreenY YellowB BlueBr BrownSK1Fig- 6. Connector PCB Circuit Diagram (Z083f Z084) ISS ASeaTalk Service Manual 15


Autohelm3 07163 4 TERMINAL BLOCK2 07119 1 'D' CONNECTOR1 3015-029 1 PCB DETAILITEMS DR'G/PART N* QTY DESCRIPTIONFig. 7. Connector PCB General Assembly ISS CSeaTalk Service Manual 17


AutohelmST6000 System1. Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Introduction 32. System Description 33. Operating / Calibration Instructions 43.1 Operation 43.2 Addition information for sailing vessels 103.3 Operating Hints 123.4 Calibration 153.4.1 Adjusting Calibration 163.4.2 Display Contrast Adjustment 173.5 Fluxgate Compass – Automatic Deviation Correction 184. Common system problems 195. Track control interfacing 195.1 Inverted data 195.2 Conversion of units 195.3 Alarm messages 195.4 NMEA Data input format 206. Special functions 216.1 Display of software version 216.2 Permanent watch alarm mode 216.3 Display Test mode 217. Service Visit to a Vessel 237.1 Onboard diagnostics 232SeaTalk Service Manual

Autohelm1. IntroductionThe ST6000 system section of this manual contains full system operating instructionsand service procedures for the autopilot. Further in depth diagnostics are availablefor each module in the relevant product sections.2. Systems descriptionThe ST6000 is a modular Seatalk compatible autopilot system that can be built up tomatch the individual requirements of most vessels and steering systems.The ST6000 course computer can be used with all Seatalk compatible control unitsand ST50 instruments and will operate the following drive units:Z039 Linear drive type 1Z037 Rotary drive type 1Z041 Hydraulic pump type 1Z081 Hydraulic pump type 0Z088 I/O SterndriveZ064 Type CR 3L/min (via Z085 Interface)Z066 Type CR 4.5L/min (via Z085 Interface)SeaTalk Service Manual 3

Autohelm3. Operating/Calibration Instructions3.1 OperationAutoCourse Changes (-1, +1, -10, +10)Push to engage automaticsteering and maintain currentheading.ORPush and hold down for 1second to return to previousautomatic heading. (Displayreturns to Auto after 10seconds).Push to alter course to port (-)and starboard (+) inincrements of 1 and 10degrees.Automatic HeadingPrevious Automatic HeadingNew Automatic HeadingStandbyPush to disengage theautopilot for manual steering(The previous automaticheading is memorised).Current HeadingTrack (see operating hints)Push to select track controlfrom Auto.Push again to return toautomatic steering.ORPush and hold down for 1second to select previous trackcontrol heading from Auto orTrack.(Display returns to Track after 10 seconds).Automatic Heading4SeaTalk Service Manual

Response• Response Level Adjustment (see Operating Hints) Response LevelPush to increase (▲) or decrease(▼) response level.To display response level withoutchanging it push both Responsekeys together briefly.Autohelm• Rudder Gain Adjustment (see Operating Hints) Rudder Gain LevelPush and hold down for 1 secondboth Response keys together todisplay rudder gain level.Within 10 seconds push once toincrease (▲) or decrease (▼)ruddergain.Rudder Gain Level(Response and Rudder levels are displayed for 10 secondsonly)IlluminationPush and hold down Display for 1second to switch on illumination.Within 10 seconds push Display toselect illumination level.Illumination Level3 = High2 = Medium1 = LowOFF = 0ff(Illumination level is displayed for 10 seconds only)SeaTalk Service Manual 5

AutohelmDisplay Key SequenceThe Display pushbutton is used to cyclethrough additional information menus.These menus depend on the autopilot modeand if navigation information is available.Auto Mode• Main DisplayStandby Mode• Main Display• Rudder Angle• Compass Heading• Navigation Displays• Rudder AngleSee section on Navigation Displays.• Navigation Displays• Watch AlarmSee section on Navigation Displays.6SeaTalk Service Manual

AutohelmTrack Mode• Main Display• Locked CourseNavigation DisplaysWith the Navigation Receiver operating inwaypoint mode, the following information canbe displayed (provided that the NavigationReceiver transmits the appropriateinformation - see Installation Handbook).• Cross Track Error• Rudder AngleThe arrows show the direction to steer torejoin the desired Track:► Starboard◄ Port• Bearing to Waypoint• Navigation Displays• Magnetic• TrueSee section on Navigation Displays.• Distance to Waypoint• Watch Alarm• Waypoint NumberSeaTalk Service Manual 7

AutohelmWatch Alarm (not available in Standby)• Engage the Autopilot in Auto TrackWindvane mode.• To select Watch alarm push Displayrepeatedly until Watch appears.Warning Messages• Off Course AlarmThe 4 minute timer is now running:-— After 3 minutes 'Watch' flashes on allcontrol units.— After 4 minutes the alarm sounds on allcontrol units.• Push Auto at any time to reset the timerto 4 minutes and silence the alarm.• To cancel the Watch alarm at any timepush Display.— Sounds if the vessel deviates from theautomatic heading by more than theselected amount for over 20 seconds.• Low Battery Alarm— Sounds if the course computer supplyvoltage falls below 11 volts for over 20seconds.• Track Mode Alarms— Sounds if no waypoint data is receivedfrom the Radio Navigation System for over20 seconds.— Sounds if the data has the incorrectformat or if an invalid flag is set.— Sounds if the cross track error exceeds0.30n.m.8SeaTalk Service Manual

Autohelm— Sounds when the target waypoint number changes. The displayed bearing is tothe new waypoint. PORT or STBD indicates in which direction the autopilot will turnonto the new waypoint bearing.Push Track to silence the alarm and automatically steer onto the new bearing towaypoint.• Manual Override Alarm(Installations with stern drive actuators only).— Sounds for 10 seconds when the autopilot is manually overridden at the steeringwheel. After 10 seconds the autopilot will return to Standby automatically.Note: Push Standby to silence an alarm and select Standby mode (unless indicatedotherwise).SeaTalk Service Manual 9

Autohelm3.2 Additional information for Sailing VesselsAutotackThe ST6000 has a built in Autotack functionwhich will turn the vessel through 100°. Thisoperates in both compass and vane modesas follows:-VanePush +1 and +10 keystogether to initiate a tackturning to Starboard.Push –1 and –10 keystogether to initiate a tackturning to Port.Note: It is important that the rudder angletransducer is accurately aligned as theAutotack function mirrors standing helm andany offset will change the initial tack angle.Wind Trim (Windvane Operation)Wind Trim allows the autopilot to besupervised by apparent wind direction. Thewind direction is read either:-— From the SeaTalk bus (requiresAutohelm ST 50 unit).OR— From an NMEA 0183 input on the controlunit.Push both red keys togetherto select Wind Trim andmaintain the currentapparent wind angle.Push and hold down for 1second both red keystogether to return to theprevious apparent windangle.Automatic HeadingPrevious AutomaticHeading10SeaTalk Service Manual

AutohelmWind Change AlarmWind Trim uses the fluxgate compass asthe primary heading reference andautomatically adjusts the compass headingto maintain the original apparent wind angle.If changes in apparent wind angle adjust theoriginal automatic heading by more than 15°the wind change alarm will sound.— The alarm is silenced by pushing bothred keys together briefly.Using Wind TrimIt is important to understand that "WindTrim" prevents over-reaction to gusts orsudden wind shifts. One minute is requiredto change the heading in response to apermanent change in apparent wind angle.Do not attempt to override the automaticsequence with the course change buttons.In gusty conditions sail a few degrees offthe wind and pay frequent attention to sailtrim and helm balance using the rudderangle indication.Performance will normally be improved byreefing headsail and mainsail a little earlyrather than too late.Display of Wind AngleIf the wind angle information is suppliedusing the NMEA 0183 input or SeaTalk bus,the apparent wind angle and tack sense (◄for port, ► for starboard) is added to thedisplay menu and accessed via the Displaybutton.• Apparent Wind Angle— The apparent Wind Angle is 35° —Starboard Tack.• Adjust Apparent Wind AngleUse the ±1 or ±10 degreebuttons to change headingand hence adjust theapparent wind angle.SeaTalk Service Manual 11

Autohelm3.3 Operating HintsResponse Level AdjustmentThe ST6000 has three response levels whichenable tighter course keeping to be achieved incertain cases:-Level 1 - Automatic Sea State ControlLevel 2 - Automatic Sea State InhibitLevel 3 - Automatic Sea State Inhibit andcounter rudder.When the autopilot is switched on, the responselevel is set to 1. This provides the bestcompromise between power consumption andcourse keeping accuracy and is suitable fornearly all situations.Increasing Response level provides tightercourse keeping at the expense of increasedpower consumption and general wear and tear.It is advisable to use the minimum responselevel necessary to achieve the desired coursekeeping accuracy. On larger power vesselslevel 3 can improve slow speed steering wherethe natural yaw damping of the vessel isreduced.Note: Level 3 is not recommended for use atplaning speeds or in rough seas.TrackTo make full use of Track control the followingsimple points should be observed:-• Always steer the vessel to within 0.1nm oftrack and bring the heading to within 5° of thebearing to the next waypoint before selectingTrack.• Always check that there are no navigationalhazards either side of the intended track.• Always maintain an accurate log withregular plots to verify the computed positionread from the Radio Navigation Receiver.• Maintain a proper lookout at all times.•Waypoint AdvanceIf the navigation receiver is transmitting thewaypoint number to the ST6000 the waypointalarm will sound whenever a new targetwaypoint is selected (see Page 9). When thealarm is sounding the ST6000 will maintain thecurrent heading and automatic track control issuspended. Check the displayed new bearing towaypoint and when it is safe to turn onto it,resume automatic track control by simplypushing Track.This accepts the new target waypoint and willsteer the vessel onto the new bearing towaypoint.The tidal offset may be very different on the newbearing, and it is good practise to check thecross track error after a couple of minutes. If thecross track error continues to increase make acourse adjustment of say 10 degrees in thedirection of the arrow. This will help the Trackcontrol correct more quickly for the new tidalvector.Automatic TrimIf Automatic Trim has been selected duringcalibration the ST6000 will correct for trimchanges. This correction can take up to oneminute to apply the rudder offset necessary torestore the set automatic heading. Large coursechanges which change the apparent winddirection, can produce large trim changes. Inthese cases the autopilot will not immediatelyassume the new automatic heading, and onlysettle onto course when the Automatic Trim hasbeen fully established.To minimise the inherent time delay thefollowing procedure may be adopted for largecourse changes.• Note required new heading.• Select Standby and steer manually.• Bring vessel onto new heading.• Select Auto and let vessel settle ontocourse.• Bring to final course with 1° increments.It is sound seamanship to make major coursechanges only whilst steering manually. In thisway any obstructions or other vessels may becleared properly and due account taken of thechanged wind and sea conditions on the newheading prior to engaging the autopilot.Rudder GainThe rudder gain level selected during initial seatrials will normally provide excellent steeringperformance over a wide range of conditions.However, it may be noticed that the autopilottends to be a little less stable on northerlyheadings in the higher latitudes of the northernhemisphere (and conversely southerly headingsin the southern hemisphere). This is caused bythe increasing angle of dip of the earth's12SeaTalk Service Manual

Autohelmmagnetic field at higher latitudes which hasthe effect of amplifying rudder response onnortherly (southerly) headings.Rudder Gain Adjustment (Sail) It is notnormally necessary to adjust the autopilotgain setting once the correct level has beenestablished during initial sea trials.Depending on the yachts individual steeringcharacteristics a change of one level mayimprove course keeping accuracy whengoing from northerly to southerly (increase)or southerly to northerly (decrease)headings.The effect may be judged by carrying out asea trial in smooth water conditions andobserving the results.Note: The effect is reversed for thesouthern hemisphere.Rudder Gain Adjustment (Powercraft) Thetendency towards northerly (southerly)heading instability is more obvious in highspeed craft and can be corrected by areduction in the rudder gain setting. Atspeeds in excess of 30 knots a reduction oftwo levels can be required on headingsbetween 315° and 045° (northernhemisphere) or 135° and 230° (southernhemisphere).Two options are available to control this:-• Manual (Low speed and displacementcraft) The rudder gain control may changeby one level when going from northerly tosoutherly (increase) or southerly to northerly(decrease) headings.The effect may be judged by carrying out asea trial in smooth water conditions andobserving the results.Note: The effect is reversed for the southernhemisphere.• Autoadapt (High speed planing craft)The ST6000 can be set to automaticallyreduce the effects of Northerly headinginstability. This feature is selected incalibration mode by entering the Latitude(see Installation Handbook, Calibration,section on 'Auto Adapt'). When selected theST6000 automatically adjusts the RudderGain depending on the compass heading,removing the need for manual adjustment.Rudder Gain/Speed Adjustment(Powercraft)High speed planning craft exhibit verydifferent steering characteristics when onand off the plane. As a result it is generallynecessary to adjust the Rudder Gain settingwhen going from displacement speed toplaning speed or vice versa. Two optionsare available to achieve this:-• AutomaticWhen the ST 6000 is used with anAutohelm ST50 Speed Instrument orTridata. Rudder Gain is adjustedautomatically with boat speed. There shouldbe no need for any manual adjustment.• Manual(No ST50 Speed/Tridata) The Rudder Gainsetting may be increased by one or twolevels when dropping from planing speed tocruise speed and decreased by the sameamount when returning to planing speeds,Note: It is important to make the gainadjustment after dropping to displacementspeed and before returning to planingspeed.Note: The adjustment of Gain with boatspeed is normally only required for highspeed planing powercraft.Unsatisfactory Steering PerformanceIf the ST6000 has been installed and set upin accordance with the instructions in theInstallation Manual it will provide excellentsteering performance over a wide range ofconditions.If performance drops but the autopilot is stillworking correctly, the following simplechecks should find the fault:-• Has a magnetic influence beenintroduced near the fluxgate compass? i.e.anchor, chain, radio equipment,loudspeaker, tools. generator etc. Checkthat the autopilot compass heading stillcorresponds with the steering compass.• Are all fuses intact, circuit breakersengaged?• Are all screw connections tight and freeof corrosion.SeaTalk Service Manual 13

Autohelm• If the autopilot fails to hold course checkthe Rudder Gain level. Has it been changedfrom the initial sea trials level (check inInstallation Manual)?• If the vessel wanders check that theRudder Reference Transducer linkage issecure with no free play.Hydraulic Drive Units only:-• Check that all unions are tight and bleedsystem to remove air.Failure of Drive Unit to DisengageThe mechanical drive actuators of theST6000 are designed to fail Safe1 - Whenpower is disconnected the drive unit willdisengage leaving the steering system freefor manual control.When Standby is selected the actuator willDisengage leaving the steering free.It is remotely possible that a fault coulddevelop which could cause the actuator toremain engaged even when Standby isselected. If this happens:-• DISCONNECT THE MAIN CIRCUITBREAKER TO THE AUTOPILOT - THESTEERING WILL IMMEDIATELY BE FREE,or• IN AN EMERGENCY THE ACTUATORCLUTCH CAN NORMALLY BEOVERRIDDEN BY TURNING THESTEERING WHEEL HARD.It is emphasised that this fault is extremelyunlikely and can be immediately correctedas described.If preferred a separate Override switch canbe fitted close to the steering position whichwill break the actuator clutch drive forEmergency Use.Stern Drive Actuator(Manual Override Option)Manual override is selected duringcalibration using the Auto Release option. Itmust only be used on installations fitted withthe stern drive actuator. When it has beenselected, the ST6000 can be overridden toallow hand steering by turning the steeringwheel. This will return the ST6000 toStandby and sound the control unit buzzerfor 10 seconds. There is a slight delaybefore the ST6000 will return to Standby.Excessive force is not required and willnot reduce this delay.With the ST6000 in Auto and clear ofobstruction turn the steering wheel toobserve the manual override. Repeat two orthree times until you are confident with itsoperation.The manual override is intended foremergency use only. The ST6000 shouldnormally be disengaged by pushing theStandby button on the control unit.14SeaTalk Service Manual

Autohelm3.4 CalibrationRecommended SettingsAs supplied the ST6000 can be switched onand tested safely without any adjustmentsto the factory calibration settings.The table below lists the suggested settingsfor sailing and power displacement andplaning power vessels. These will providegood performance for initial sea trials andcan be fine tuned later to optimiseperformance.Vessel TypeDisplacement PlaningFactory preset Set toRudder Gain(level) 5 2Rate Gain(level) 2 1Rudder AngleLimit (degrees) 30 30Turn Rate Limit(degrees/sec) 20 5Cruise Speed(knots) 8 25Off CourseAlarm (degrees) 20 20Trim Level 1 1Auto Adapt OFF ONSelecting and Exiting from Calibration ModeTo select calibration mode:-• Push Standby.• Push and hold down for 2 seconds,Track and Display together.• Repeat push and hold down for 2seconds, Track and Display together toenter calibration mode.To exit calibration mode at any point;a) Saving any changes made:-• Push and hold down for 2 seconds,Track and Display together.b) Ignoring any changes made:-• Push Standby.Autopilot Drive Unit TypeMechanical Stern HydraulicDriveFactory Set to Set topresetDrive Type 3 3 4Rudder1PositionDeadband(level) See3.8 1 1AutoReleaseOFF ON OFFSeaTalk Service Manual 15

Autohelm3.4.1 Adjusting CalibrationIn calibration mode, the Display button isused to scroll through the menu. Thedisplayed value is adjusted using theResponse buttons (hold button down for fastscroll).• Rate of Turn Limit, 5° to 20°/sec.• Cruise Speed, for Track modeoperation, 4 to 60 knots.• Rudder Gain, levels 1 to 9, (see 5.6)• Off-Course Alarm, 15° to 40° angle.• Rate Gain, levels 1 to 9, (see 5.7)(Counter Rudder).• Automatic Trim, (see 5.4).• Rudder Angle Limit, 15° to 40° (see 3.6).• Remote Control Identifier. (For FutureUse).16SeaTalk Service Manual

AutohelmAutopilot Drive Unit Type.and in the Southern Hemisphere.1 = Future Use2 = Future Use3 = Mechanical with Rudder Reference4 = Hydraulic with Rudder Reference• Auto Release (see 3.8).• Rudder Position Deadband (levels 1 to9), (See 3.7).• Northerly/Southerly Heading InstabilitySelect HemisphereN (North)S (South)0 = OFF1 = ONThe Auto Release facility is designed toprovide Emergency Manual Override whenused with the Autohelm Stern DriveActuator.For all other Drive Systems Auto Releasemust be selected "OFF" (0).3.4.2 Display Contrast AdjustmentThe LCD Contrast can be adjusted to suit awide range of control unit viewing angles.• Push display and track togethermomentarily.• Push response ▲ to increase contrast(suits viewing from below),• Push response ▼ to decrease contrast(suits viewing from above).• Adjust the display for optimum viewing.• Push display and track togethermomentarily to store selection and return toprevious operating mode.Enter Local Latitude using Response Keys.Atypical display in the Northern Hemispherewould be:SeaTalk Service Manual 17

Autohelm3.5 Automatic Deviation CorrectionThe ST6000 will correct the fluxgate compass for operation in most deviatingmagnetic fields. This should be carried out in calm conditions preferably in flat water.• To select compass adjust Push and hold Standby for 1 second.Keeping boat speed below 2 knots, turn the vessel slowly so that it takes at least 3minutes to complete 360°. Keep turning until control unit beeps, and the displaychanges to show the amount of deviation the autopilot has corrected:-Note: If the amount exceeds 15°, it is recommended the fluxgate should be re-sited.• Use the course change buttons to adjust the displayed heading until it agrees withthe steering compass or a known transit bearing.Note: 000° is always followed by OFF. This will suppress the display of compass andautomatic headings on the control unit.• To exit compass adjust and store the compass settings push and hold Standbyfor 1 second.• To exit compass adjust without saving any new settings push Standbymomentarily.18SeaTalk Service Manual

Autohelm4. Common system problemsProblem Cause SolutionsTo be updated as necessary““““5. Track control interfacingIn most cases interfacing the ST6000 to either a GPS, Decca, Loran or SatelliteNavigation system is a simple and straight forward task so long as the requirementsset out in section 6 of the installation manual are met. There are however a fewexceptions.5.1 Inverted DataSome receivers, notably some of the Furuno range and early Navstar models,transmit data in an inverted format with respect to 5V. This is easily seen as the dataline will idle high with respect to 0V in between data transmissions. In these casesthe NMEA cable on the rear of the control unit must be wired with the red wireconnected to 5V (this is normally available on the receiver terminal block), and theblue wire connected to the data line.5.2 Conversion of Units.All data containing units of distance will be converted to Nautical miles by the ControlUnit. Therefore any receivers displaying Cross Track Error or Distance To Waypointin either Kilometres of Statute miles etc will have their data displayed on the controlunit in Nautical miles.5.3 Alarm MessagesTrack mode has 3 alarm messages:-1. No dataIf a standard NMEA sentence is not received by the ST60002. Data error3. Large XTEThe ST6000 has recognised the incoming data as NMEA but hasdetected an invalid flag. This is normally due to poor signal strength atthe receiver.Cross track error greater than 0.3NM.Errors 1 and 2 can provide valuable information as to where an installation problemmight lie. The 'No data' message indicates the ST6000 is not receiving NMEA dataand carries a high probability of a wiring error between the receiver and the pilot. The'data error’SeaTalk Service Manual 19

Autohelmmessage indicates the ST6000 is receiving data recognised as NMEA but has aninvalid flag set. This is normally due to the receiver having a low signal strength or ahigh noise figure.5.4 Autohelm 6000 NMEA 0183 data input formatThe 6000 must receive Cross Track Error data at least once every 30seconds.If a display of Waypoint Bearing, Distance or Number or the Waypointadvance facility is required then this information must be received atleast once every 30 seconds.All NMEA data is read into a buffer thus enabling the 6000 to copewith delays between characters and delays between sentences.All Talker identifier characters, ie RA, DE, LC etc. are ignored allowinginterface with any type of equipment so long as the sentence type isone of the following :-Apparent wind speed and angle can be received from any external equipmenttransmitting the N.M.E.A VWR header. The ST6000 will only display apparent windangle but will convert and retransmit both apparent wind speed and direction on theseatalk bus. This information can then be displayed on an ST50 wind instrumentacting as a repeater.TrackControlBearing toWaypointDistance toWaypointWaypointNumberApparent WindSpeed and DirectionXTE APB WDR APB VWRXTR BPI WDC APAAPA BWR BPI BPIAPB BWC BWR BWRRMB BER BWC WDRBEC BER BWCRMB BEC WDCRMBRMBBODWCVBERBEC20SeaTalk Service Manual

Autohelm6. Special Functions6.1 Display of Software VersionIt is possible to display the version number of both course computer and control unitsoftware installed in a particular system. This is achieved by pressing both the +10and -10 keys together for 2 seconds and releasing the display will show the controlunit version (65 followed by version number) for 10 seconds followed by the coursecomputer version (66 followed by version number). The pilot must be in standbymode at the time. Each version is displayed for 10 seconds before the pilot revertsback to standby. A software history for each product is shown in the relevant servicesections.6.2 Permanent Watch Alarm ModeThe ST6000 autopilot can be set up with a permanent watch alarm mode, as requiredby the Sea Fish Industry authority (SFIA).It must be stressed that the selection of this mode is permanent and can onlybe reversed by returning the course computer to Nautech.Permanent watch alarm is achieved by first entering the calibration menu. Once incalibration, regardless of display message, press the Auto, Standby, and Track keystogether for 1 second before releasing. The display will now show 'SELECT WATCH'.The user now has 10 seconds to select permanent watch alarm mode by againpressing Auto, Standby and Track together for 1 second. The display will then show'WATCH ON1 for 10 seconds before reverting back to 'CAL1. A normal exit fromcalibration mode must now be executed.6.3 Display Test ModeAll display segments on the control unit can be switched on by pressing the +10, -10,Standby and Display keys together. This mode can only be accessed after the unithas been powered up with the yellow data wire open circuit.SeaTalk Service Manual 21

Autohelm7. Service visit to a vesselWhen a service visit to a vessel is made the most common fault encountered is likelyto be poor connections or inadequate power supplies. These should be thoroughlychecked before the service visit diagnostic procedure is carried out. When trying tolocate a fault it should be remembered that most failures will occur in the CourseComputer with the Control Units as the next most likely.It should be noted that the calibration variables and auto deviation correction willrequire re-setting if either the course computer, its PCB or its Software areexchanged. Similarly if the Control Unit PCB is exchanged the display contrast willrequire re-setting. Procedures for carrying out both these operations are given insection 3.Always note the course computer calibration settings before removing from thevessel.22SeaTalk Service Manual

Autohelm7.1 Service Visit - Diagnostic ProcedureOn arrival check for bad connections and for inadequate power supplies. If the system stillexhibits a fault, then use the diagnostic procedure outlined below.SeaTalk Service Manual 23


AutohelmST6000 Control Unit (Z124)1. Service Procedures2. Technical InformationSeaTalk Service Manual 1

Autohelm1. Service ProceduresContentsPage1. Description 32. Dismantling 33. Reassembly 34. Display Contrast Adjustment 45. Functional Test 66. Product History 87. Software History 88. Spares Numbers 8IllustrationsFig. 1. General assembly 52SeaTalk Service Manual

Autohelm1. DescriptionThe Z124 control unit is Seatalk compatible and consists of a single PCB built usingsurface mount technology. The unit can be functionally tested (figure 3) without theuse of special equipment other than a seatalk cable with a seatalk plug at one endand bared cores at the other.If a control unit or its PCB are replaced the display contrast will require re-setting.This should be carried out aboard the vessel following the instructions given insection 3.2. DismantlingAfter removing the unit from the boat and returning to the service centre. Place facedown on a clean, light foam surface. Preferably conductive.1. Unscrew and remove the 4 case securing screws from the rear cover. Push eachcable loom assembly back through its grommet so as to obtain working clearance tothe PCB (fig 1)Note: if cables are very tight in grommets apply a small smear of silicon grease toouter sheath, (grease can be wiped off after reassembly).If removing the PCB assembly it will be necessary to de-solder the cables from thePCB. Great care should be exercised when de-soldering so as not to damage thepads on the PCB.2. Unscrew and remove the 9 screws which secure the PCB to the facia.Note: Do not at this stage remove the screws which secure the LCD assembly to thePCB. Refer to figure 1 to clarify which screws to remove.3. Before removing the LCD ensure that lint free and preferably anti static finger cotsare worn to prevent the LCD or elastomers getting dirty or greasy.4. Unscrew and remove the 3 LCD housing retaining screws (fig 1). Be careful to holdthe LCD surround, LCD, and diffuser when dismantling. Lift away from the PCB andstore.3. Re-assemblyRe-assembly is a straight reversal of the above procedure but note the followingpoints:-1. Ensure the LCD is correctly orientated relative to the PCB (fig 1).2. Ensure the diffuser is correctly orientated relative to the LCD and PCB (fig 1).3. Note the correct orientation of the various looms and core colours to the PCB pads(fig 1).4. Ensure that the board is tightened down sequentially to ensure the load is evenlyspread.SeaTalk Service Manual 3

Autohelm5. Pull the loom assemblies back through the grommets when lowering the cover toensure that the cables do not bunch up inside the cover and foul the PCB on reassembly.6. Refit the cover.7. Re-check for full function after re-assembly to check the LCD has not beendamaged or looms incorrectly soldered. Adjust LCD contrast if necessary.4. Display Contrast adjustmentThe LCD Contrast can be adjusted to suit a wide range of control unit viewing angles.Push display and track together momentarily.Push response ▲ to increase contrast (suits viewing from below).Push response ▼ to decrease contrast (suits viewing from above).Adjust the display for optimum viewing.Push display and track together momentarily to store selection and return to previousoperating mode.4SeaTalk Service Manual

AutohelmFig. 1.SeaTalk Service Manual 5

Autohelm4. Z124 Control Unit Functional Test6SeaTalk Service Manual


Autohelm5. Product History - Control Unit (2124)Change Serial number Comments030001 production start6. Software History - Control Unit (Z124)Version Change Serial No65E Product launch 0300017. Spares numbers - Control unit (Z124)Item Catalogue no CommentsDouble skin mounting kit Q003 allows fixing to up to 4" thick bulk headsPCB assemblyQ027LCDQ028Protective coverD1238SeaTalk Service Manual

Autohelm2. Technical InformationContentsPage1. Circuit Description 21.1 Power Supply 21.2 Microprocessor and Program Memory 21.3 LCD and Display Driver 21.4 Negative Rail Generator 21. 5 N.M.E.A Interface 21.6 Seatalk Bus Transmit and receive. 21.7 Keypad Operation 21.8 Buzzer Operation 31.9 Illumination DriveIllustrationsFig. 1 . Circuit Diagram 4Fig. 2. PCB Assembly/Parts List 5SeaTalk Service Manual 1

Autohelm1. Control Unit PCB Circuit descriptionFig. 4. Circuit DiagramFig. 5. PCB Assembly/Parts List1.1 Power supplyIncoming power is routed to the PCB via PL1 and SKT1. Dl and D2 protect againstreverse connection of the supply. IC1 is a 5v regulator and can also reset themicroprocessor, via TR1, should the supply voltage fall below 6V.1.2 Microprocessor and program memoryIC6 is an Intel 80C32 microprocessor. It can access up to 32k bytes of programmemory (IC5) via the latch IC4. A clock signal for the microprocessor is provided byan 11MHz ceramic resonator (XL1), and associated capacitors CIS and C16.Capacitors C17, C18 and C19 provide decoupling.1.3 LCD and Display driverThe LCD is a Nautech custom part. The display is driven by a Hitachi Led driver (IC3)deriving its drive voltages from resistor chain R27-R30 and VR1. Communication tothe microprocessor is via a 4 bit parallel bus (DB4 to DB7) and the three control linesE,R/W and RS. Capacitors C8 and C10 provide decoupling and resistor R26 theclock signal for IC3.1.4 Negative Rail GeneratorA negative voltage rail is required by the LCD display and is generated by a switchingregulator formed by TR6,D5 and D6. A 4.8kHz waveform is generated from themicroprocessor P3.4 (pin no. 16). This drives a charge pump, via transistor TR16,pumping charge from C20 via D6 to C21. The negative rail is then stabilised by D5and R49.1.5 N.M.E.A InterfaceNMEA data is fed to the control unit via PL2 and isolated from the rest of the circuitusing the opto-isolator (IC7). Diode D3 provides input reverse connection protectionand resistor R15 is tuned to give the desired bandwidth of operation. The output fromIC7 is connected to the microprocessor Port P3.2 (pin 14). Capacitor C7 providesdecoupling.1.6 Seatalk Bus Transmit and ReceiveSeatalk transmit and receive circuitry consists of TR9, 10, 11 ,12, 13, 14 and 15 andtheir associated components. Data transmission is at 4800 baud with a low start bitand line idling high. TR9 and TR13 provide high and low output respectively, whilstTR14 and R45/46 give overload protection to Trl3 in the event of misconnection.TR10 and TR11 allow the microprocessor to monitor its own transmissions and alsoto receive data from other units on the bus.1.7 Keypad operationThe 10 button keypad is interfaced to the microprocessor via 2 dual input multiplexerIC's.2SeaTalk Service Manual

AutohelmEach key is read in turn when the relevant channel is selected via pins p3.5 and p3.6.1.8 Buzzer OperationTR2 and TR3 are configured as an astable multivibrator with a nominal frequency of2.7kHz. TR7 and 8 are used to switch the buzzer with TR7 acting as an inverter toturn the buzzer off during a microprocessor reset.1.9 Illumination DriveTR10, 12 and 16 provide a constant current drive for lamps LP1 and LP2. Thecurrent is set by resistors R11 and R12. TR6 is an inverting buffer to turn off the lightsduring a microprocessor reset. Illumination level's are given by pulse widthmodulation of drive line P3.3 (pin 15).SeaTalk Service Manual 3


AutohelmST6000 (Z124) Control Unit Circuit DiagramISS ESeaTalk Service Manual 5


AutohelmNOTES1. ALL SURFACE MOUNT CAPACITORS ANDRESISTORS TO HAVE NICKEL BARRIERSOLDER PLATED TERMINATIONS.2. ITEM 47 (15085) & ITEM 49 (15127) TO LIEFLAT ON PCB.3. DO NOT FIT COMPONENTSR45,R47,R49,C9,C11 C12,C13,D5 AND VR1.4. OPTION TO ASSEMBLE PCB WITH EITHERXL2 OR XL1/C15.C16.XL2 IS THE PREFERRED OPTION5. THIS ITEMS LIST HAS NOT BEENRATIONALISED FOR 'IN HOUSE' BUILD.ITEMS 93041000P.91051K AND 91061K2 ARENON PREFERRED SURFACE MOUNTCOMPONENTS.47 15127 1 CERAMIC RESONATOR (CERALOCK) BUILT IN LOADCAPACITANCE CST 11.0MT (3 PINS) XL2OR46 930I33P 2 0805 CAPACITOR 33pF ±5% 50V COG C15, C16&45 15085 1 CERAMIC RESONATOR 11Mhz (CSA 11.0MT) XL1EITHERAND44 9408HD44780 1 LCD DISPLAY DRIVER HD44780 (HITACHI) OR KS0062 (SAMSUNG) IC31 AND43 05018 TRANSISTOR BC337 NPN (TO BE ASSEMBLED WITH TR41 MAXIMUM LEAD LENGTH OF 4MM).OR42 9501BCX68 1 TRANSISTOR SOT 89 BCX68 NPN TR4EITHERPLUS4! 940274253 2 HCMOS (DUAL 4 TO 1 MULTIPLEXER) 74HC253 IC8, IC940 94006N139 1 OPTO ISOLATOR 6N139 LEADS TO BE FORMED FOR IC7BUTT JOINT CONNECTION (i.e. HP'S OPTION 100)39 940680C32 MICRO ROM LESS 80C3212 MHz PLCC IC638 940374373 HCMOS LATCH 74HC373 IC437 940093061 EEPROM 16x16 M9306M1 [SGS] OR NATIONAL SEMICONDUCTOR IC236 04049 VOLTAGE REGULATOR LM2925 IC135 9500BC807 TRANSISTOR SOT 23 BC807 PNP TR934 9500BC817 14 TRANSISTOR SOT 23 BC817 NPN TR1,3,5,6,7,8,10,11,12,13,14,15,1633 9200BAV99 2 DIODE SOT 23 BAV99 D4, (D5),D6 # - SEE NOTE 332 9200BAS19 3 DIODE SOT 23 BAS19 D1,D2,D331 93041000P 1 0805 CAPACITOR 1000pF ±10% 50V X7R C1430 930522N 3 1206 CAPACITOR 22µf 5% 50V X7R C2,C5,C629 93070U1 10 1206 CAPACITOR 0.1µF ±20% 50V X7R D1,7,8,10,17,18,19,22,23,2428 9314470P 0 0805 CAPACITOR 470pF ±20% 50V X7R (C9,C11,C12,C13} # - SEE NOTE 327 931110U 1 CAPACITOR SOLID TANT 10µF ±20% 6V3 (SIZE 0) C2126 03063 2 CAPACITOR ELECTROLYTIC 100uF ±20% 25V MIN 07.5 MAX C3,C425 93091U 1 CAPACITOR SOLID TANT 1µF ±20% 16V(SIZE A) C2024 9106100K 1 1206 RESISTOR 100K 5% 0.125W R1523 9105 IK 4 1206 RESISTOR 1KO 2% 0.125W R27,R28,R29,R3022 9106680R 0 1206 RESISTOR 680R 5% 0.125W (R49)21 9106120R 1 1206 RESISTOR 120R 5% 0.125W R1120 910591K 1 1206 RESISTOR 91K 2% 0.125W R2619 91068R2 4 1206 RESISTOR 8R2 5% 0.125W R46,(R47),R48,R50,R53 # - SEE NOTE 318 910639K 3 1206 RESISTOR 39K 5% 0.125W R31,R37,R3817 910622K 1 1206 RESISTOR 22K 5% 0.125 W R3416 910615K 1 1206 RESISTOR 15K 5% 0.125W R3615 910612K 19 1206 RESISTOR 12K 5% 0.125W R1,2,3,6,7,10,16,17,18,19,21,22,23,24,25,35,39,4114 91064K7 4 1206 RESISTOR 4K7 5% 0.125W R4,R14,R40,R5213 91062K2 3 1206 RESISTOR 2K2 5% 0.125W R13,R33,R4212 91061K2 3 1206 RESISTOR 1K2 5% 0.125W R9,R43,R4411 9106470R 2 1206 RESISTOR 470R 5% 0.125W R5,R810 9106390R 2 1206 RESISTOR 390R 5% 0.125W R32,R519 910313R 1 1206 RESISTOR 13RO 1% 0.125W R12,(R45) # - SEE NOTE 38 9107 IK 0 CHIP TRIMMER RESISTOR 1K MURATA RVG 4F03A-102VM (VR1) # - SEE NOTE 37 15087 1 BUZZER KBS-27DB-3T BZ16 06025 10 CONTACT CLICKER OOK-73470 S1,S2,S3,S4,S5,S6,S7,S8,S9,S105 26006 1 RIVSCREW 1712-3507 (AVDEL)4 15039 1 HEATSINK REDPOINT TV583 07164 1 28 PIN SOCKET2 3015-025 1 6000 CONTROL UNIT PCB DETAIL1 3010-036 10 CLICKER SEALITEMS DR'G/PART N* QTY DESCRIPTIONST6000 (Z124) Control Unit PCB AssemblySeaTalk Service Manual 7


AutohelmST6000 Course Computer (Z123)1. Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Disassembly 33. Reassembly 34 Functional Test 55. Product History 106. Software History 107. Spares Numbers 10IllustrationsFig. 1 . General Assembly 42SeaTalk Service Manual

Autohelm1. DescriptionThe ST6000 course computer is SeaTalk compatible and consists of a single PCBcontaining both the course computer and power amplifier circuitry. It is built usingsurface mount technology and available for 12v operation only.Note: If the course computer or its PCB are replaced, calibration values previouslyaltered from the factory settings will require resetting. Also the Fluxgate Compass willrequire re-linearising (auto deviation correction). Both of these procedures areoutlined in the ST6000 system section.It is essential the cable used for the single DC supply is of adequate gauge otherwisethe system may reset back to standby mode when the drive motor operates.The table below gives a guide to cable size required. The length quoted is the totalcable length from the main distribution panel to the course computer, plus the lengthfrom the course computer to the drive unit.Drive Unit and Power Supply Cable SizeCable length Cable type Copper area Cable gaugeup to 7m 50/0.25 2.5mm 2 12 awgup to 10m 56/0.3 4.0mm 2 10 awgup to 16m 54/0.3 6.0mm 2 8 awg2. Disassembly1. Unscrew and remove the 2 countersunk screws securing lid on terminal boxsection and lift off lid.2. Unscrew and remove the 2 thumb nuts securing extrusion assembly to terminalbox unit and pull extrusion assembly away from terminal box.3. Unscrew and remove the 8 pan head screws securing both the connector coverand extrusion end cap mouldings.4. Remove the two heatsink location screws (ensure associated nuts and washersare recovered).5. Carefully withdraw the PCB assembly.3. Re-assemblyIn all cases re-assembly is a reversal of the dismantling procedure but note thefollowing:-Apply a small amount of loctite 270 (or equivalent) to the threads of the two heatsinklocation screws after they have been installed.SeaTalk Service Manual 3

AutohelmCourse Computers (Z083, Z084) - General Assembly4SeaTalk Service Manual

Autohelm4. Functional TestThe course computer can be functionally checked as follows; Pre-checked equipmentrequired:SeaTalk Control Unit(Z124)Fluxgate Compass (Z105 or Z130)Pushpit vane transducer(Z087)Rudder Reference Transducer (Z060)Terminal PCB(Q030)Terminal BlockMultimeterMotor (small AH1000 type)(M080)Power Supply (Min rating 10A)SeaTalk Cable(D131)Procedure1. Connect all units to course computer and terminal PCB.2. Position the rudder reference transducer arm diametrically opposite the cablegland.3. Connect the 12v supply (do not switch on) and refer to the bench testing (stage 1)procedure that follows.SeaTalk Service Manual 5

Autohelm4.1 Course Computer Bench Testing (Stage 1)6SeaTalk Service Manual




Autohelm5. Product History - Course Computer (ST6000)Change Serial No CommentsProduction start 0300016. Software History - Course Computer (ST6000)Version Change Serial No66F Product launch 03000166G Improved Trim function 5005717. Spares numbers - Course Computer (ST6000)Item Catalogue No CommentPCB Assembly Q031 Main course computer PCBPCB Assembly Q030 Terminal box PCB10SeaTalk Service Manual

Autohelm2. Technical InformationContentsPage1. Circuit Description 21.1 Power Supply 21.2 Microprocessor and program memory 21.3 Power Amplifier 21.4 Analogue to Digital converter 21.5 Clutch Drive 31.6 Seatalk Bus Transmit and Receive 31.7 Fluxgate Drive 31.8 E2 Prom 31.9 Supply Voltage Monitor 3SeaTalk Service Manual 1

Autohelm1. ST 6000 Course Computer Circuit DescriptionCircuit diagram Fig. 1.PCB Assembly/Parts List Fig. 21.1 Power SupplyIncoming power is routed to the PCB. via the 'D' connector socket SKI. VI providessuppression against any voltage spikes present on the incoming DC supply whilstD15 protects against accidental reverse connection of the supply. 1C 1 is a 5vregulator with an integral reset function which resets the microprocessor, via Tr9,should the supply voltage be insufficient to maintain regulation.1.2 Microprocessor and Program memoryIC2 is an Intel 80C32 microprocessor with 256 bytes of on board Ram. It canaccess up to 32K bytes of programme memory in IC7, via the latch IC6.A Clock Signal for the microprocessor is provided by an 11MHz ceramic resonator(XL1) and C15 & C16. Alternatively. XL2 can be used which combines all threecomponents in one package.1.3 Power AmplifierTR23, 24, 25 and TR26 are configured to form a power amplifier capable of drivinga motor in four modes:-1. Drive right2. Drive left3. Short circuit motor (Brakes Motor)4. Open circuit motorMode 3 is used to stop the motor quickly by switching Tr23 and 25 On and TR24and 26 Off. Mode 4 allows the motor speed to be measured by switching off all ofthe power transistors.All four modes are controlled via pins 8 and 9 of the microprocessor IC2.1.4 Analogue to digital ConverterIC3.4 and 9 form a software driven analogue to digital Converter. IC3 and 9 are 8channel multiplexed analogue switches routing all analogue signals, (see tablebelow), through to IC4 which is configured as an integrator. C9 is discharged at aconstant rate triggering the comparator IC5 as it reaches a level of approximately0.53v. The output of the comparator is connected to the microprocessor allowingmeasurement of the discharge time which is directly proportional to the analogueinput. Analogue channels:-IC3 Channel 0 Reset integratorChannel 1 Integrator discharge signalChannel 2 Fluxgate sense AChannel 3 Fluxgate sense B2SeaTalk Service Manual

AutohelmChannel 4 Feedback 1 (FB1)Channel 5 Feedback 2 (FB2)Channel 6 Not usedChannel 7 Not usedIC9 Channel 0 Not usedChannel 1 Not usedChannel 2 Rudder Reference (RUDDER)Channel 3 Supply Monitor (INPUT VOLTS)Channel 4 Not usedChannel 5 Not usedChannel 6 JoystickChannel 7 Not used1.5 Clutch DriveTR10, 11 and 12 switch a nominal 12v onto the actuator clutch whenever pin 15 ofthe microprocessor (IC2) is low at 0v.1.6 Seatalk Bus Transmit and ReceiveSeatalk transmit and receive circuitry consists of TR1,3,4,5,18 and 19 and theirassociated components. Data transmission is at 4800 baud with a low start bit andline idling high. TR1 and Tr2 provide high and low drive respectively, whilst TR3 andR1 give overload protection to Tr2 in the event of misconnection. Tr4 and Tr5 allowthe microprocessor to monitor its own transmissions and also to receive data fromother units on the bus.1.7 Fluxgate driveIC2 produces bursts of 8KHz pulses on pin 2 which are then fed through Tr6,7 and 8and AC coupled to the fluxgate via C3.1.8 E2 promIC8 is an E 2 PROM which allows calibration values to be stored and recalled eachtime after power up. Sequential data is written to the e2 prom on pin 3 and readback on pin 4.1.9 Supply voltage monitorR53 and R54 scale down the supply voltage and feed it through to the A/D converterto enable the microprocessor to transmit a warning on the Seatalk bus if the supplyvoltage drops below 11.2v for 10 seconds or more.SeaTalk Service Manual 3


AutohelmST6000 (Z123) Course Computer Circuit DiagramISS ASeaTalk Service Manual 5


Autohelm65 EITHER 1 CERAMIC RESONATOR 11MHz CERALOCK CSA 11.0MTXL 164 2 CAPACITOR 1206 33pF ±5* 50V C15, 1663 OR 1 CERAMIC RESONATOR CERALOCK CST 11.0MT(3 LEGS)XL 1NOTE:-THIS 1st STAGE PCB ASSY RELATES TOCURRENT BUILD STANDARD OF 3015-040 ISSUE DAND62 22016 3 NUT61 15014 6 INSULATING BUSH60 23029 3 WASHER59 21114 3 SCREW58 26005 2 RIVSCREW (1712-3509)57 02032 1 DIODE MUR1510 D1556 05028 2 TRANSISTOR SM2174A TR23,2555 05029 2 TRANSISTOR SM2184A TR24,2654 03036 2 CAPACITOR 1µF ±m 25V MIN TANTALUM BEAD C23,2453 03023 1 CAPACITOR 1000µF 3 60V M1N C2152 1 CAPACITOR 1206 22nF ±20$ X7R 50V C551 1 EEPROM 16 x 16 M9306M1 {SURFACE MOUNT) IC850 1 LATCH 74HC373 (SURFACE MOUNT) IC649 2 F.E.T.OP.AMP CA3130M (SURFACE MOUNT) IC4,548 2 ANALOGUE SWITCH CD74HC4051M (SURFACE MOUNT) IC3,947 1 MICRO ROMLESS 80C32 12MHz PLCC CMOS IC246 1 5v REGULATOR LM2925 IC145 05035 1 TRANSISTOR PNP BDW94B TR1244 13 TRANSISTOR SOT23 NPN BC81743 6 TRANSISTOR SOT23 PNP BC807 TR1, 8, 21, 22, 27, 2842 2 CAPACITOR 1206 0.01µF ±20% 25V MIN C22.2541 03031 2 CAPACITOR ELECTROLYTIC 100µF +80% -20% 5V MIN RADIAL 10DIA C6.2640 1 CAPACITOR CASE A 2.2µF ±20% 6V3MIN TANTALUM C339 1 CAPACITOR 1206 470pF ±20% 50v C203837 12 CAPACITOR 1206 0. 1µF ±20% 50v C2,7,8,10,11,12,13,14,17,18,27,28CAPACITOR 120 100pF ±20% COG 50v OR36 1 CAPACITOR POLYSTYRENE 1000pF ±1% 10v MIN (03053)C935 1 CAPACITOR 1206 1000pF ±20% 50v C134 2 DIODE SOT23 BAW56 D4,933 5 DIODE SOT23 BAS 19 D11,12,14,18,1932 1 DIODE SOT23 BAV99 D231 01157 2 RESISTOR WIRE-WOUND 82R ±5% 2.5W R106, 1143029 2 WCR 1206 (FUTURE USE) R69,7228 2 WCR 1206 33K 1% 0.125W R30,4327 1 WCR 1206 3K9 5% 0.125W R2326 1 WCR 1206 470K 5% 0.125W R6825 1 WCR 1206 82R 1% 0.125W R6224 5 WCR 1206 5K6 1% 0.125W R53, 59,73,74,9023 9 WCR 1206 68K 1% 0.125W22 3 WCR 1206 270R 1% 0.125W R28,29,6521 6 WCR 1206 1K 1% 0.125W R26,27,31,32,54,6420 6 WCR 1206 1K5 5% 0.125W R16,18,102,103,116,11919 4 WCR 1206 220R 5% 0.125W R104,107,113,11518 3 WCR 1206 4K7 5% 0.125W R12,100,12017 1 WCR 1206 15K 5% 0.125W R1016 9 WCR 1206 10K 5% 0.125W R9,14,15,22,24,25,66,67,9315 1 WCR 1206 22K 5% 0.125W R814 6 WCR 1206 2K2 5% 0.125W R6,7,101,105,117,11813 2 WCR 1206 1K8 5% 0.125W R77.7812 1 WCR 1206 1K2 1% 0.125W R6111 8 WCR 1206 1K2 5% 0.125W R4,5,10,110,122,123,12410 1 WCR 1206 390R 5% 0.125W R39 3 WCR 1206 39K 5% 0.125W R2,11,138 5 WCR 1206 8R2 5% 0.125W R1,20,21,70,717 1 VARISTOR ZNR TYPE D ERZC07DK270 V165 3022-003 1 HEATSINK4 3010-073 2 CUSTOM SIL PAD3 07164 1 1C SOCKET (28 PIN) SK22 07119 1 'D' CONNECTOR 25 WAY (FEMALE) SK11 3015-040 1 ST6000 COMPUTER PCB DETAILITEMS DRG/PART N° QTY DESCRIPTIONST6000 (Z123) Course Computer PCB AssemblySeaTalk Service Manual 7ISS D


Autohelm5 07212 2 TERMINAL BLOCK (2 WAY) TB5,64 07108 2 TERMINAL BLOCK (3 WAY) TB2,43 07109 1 TERMINAL BLOCK (4 WAY) TB1,32 07118 1 'D’ CONNECTOR SK11 3015-041 1 PCB DETAILITEMS DR'G/PART N° Q'T'Y DESCRIPTIONST6000 (Z123) Terminal PCB AssemblyISS A1SeaTalk Service Manual 9


AutohelmType CR Interface Box (Z085)1. Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Functional Test 33. Operation non Autohelm power packs 42SeaTalk Service Manual

AutohelmService Procedures Type CR Interface Box (Z085)1. DescriptionAll type CR systems are driven with a standard course computer and terminal boardwhich interfaces to a type CR interface box (Z085). The same interface box is usedfor both 12V and 24V systems and can be functionally tested by using the followingprocedure.2. Functional TestConnect + 12V to clutch (+) and battery (+). Connect 0V to clutch (-) and battery (-).Confirm with a multimeter that 12V is present across the bypass connections.Remove the +12V from clutch (+) and confirm that 0V is present across the bypassconnections.SeaTalk Service Manual 3

Autohelm3. Operation with non Autohelm Power PacksIf the Type CR Interface Box is to be used to drive non-Autohelm power packs thefollowing points should be noted:1. Solenoid pull-in voltage 2V.3. Solenoid nominal operating voltage should be the same as the pilot.4SeaTalk Service Manual

Autohelm2. Technical InformationContents1. Circuit DescriptionIllustrationsFig. 1. Circuit DiagramFig. 2. PCB AssemblyFig. 3. Parts ListPage2345SeaTalk Service Manual 1

Autohelm1. Type CR Interface Box PCB Circuit DescriptionThe course computer clutch signal activates RLY1 which in turn supplies current to abypass valve, if fitted. D1 suppresses any inductive spikes produced when the valveis switched and D2 protects against supply misconnection.Each solenoid drive is derived by connecting one side of the solenoid to a motorterminal and the other side to 0V.2SeaTalk Service Manual

AutohelmFig. 1. Z085 Type CR Interface Box Circuit Diagram ISS BSeaTalk Service Manual 3


AutohelmFig. 2. Z085 Type CR Interface Box PCB Assembly ISS BSeaTalk Service Manual 5


Autohelm7000 Type CR Parts ListItemDR'G/Part NoPCB detail 3015-038Diode MR751 D1 02031Diode (Fast Recovery) MR850 D1 02036PCB Connector 07-212Relay T9030A RL1 15057Dust Cover 15111SeaTalk Service Manual 7


AutohelmRudder Reference Transducer (Z131)Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Functional Test 3IllustrationFig. 1. Rudder Reference Body AssemblyFig. 2. Rudder Reference General Assembly452SeaTalk Service Manual

Autohelm1. DescriptionThe Z131 Rudder Reference contains a single turn 5k ohm plastic potentiometer toprovide the autopilot with rudder position information. When replacing, correctinstallation is vital if optimum steering performance is to be achieved. The RudderReference unit arm movement is limited to +/-60 degrees. Care must be taken toensure that the arm is opposite the cable entry when the rudder is amidships. Failureto do this could result in damage to the Rudder Reference if the arm is driven into itsend stops by the steering system. Once detected as faulty the Rudder Reference unitshould be replaced as a complete unit.2. Functional TestThe Rudder Reference unit, when disconnected from the autopilot, can befunctionally tested by checking the following resistance measurements:-Cable colour Arm position ResistanceGreen/Red Any position 5k ohm +/-5%Blue/Green Anticlockwise stop 1.66k ohm +/-10%Blue/Green Clockwise stop 3.33k ohm +/-10%SeaTalk Service Manual 3

AutohelmZ131 Rudder Reference Body Assembly4SeaTalk Service Manual

AutohelmZ131 Rudder Reference General AssemblySeaTalk Service Manual 5


AutohelmFluxgate Compass Transducer (Z130)Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Functional Test 33. Magnetic Deviation 34. Gimble Support Bracket Installation 55. Fluxgate Sensor Replacement 56. Product History 67. Spares Numbers 6IllustrationsFig. 1. Fluxgate General Assembly 42SeaTalk Service Manual

AutohelmFluxgate Compass Transducer (Z130)1. DescriptionThe Z130 Fluxgate Compass Transducer contains a precision Fluxgate sensor. Thiscan be replaced by following the procedures in Section 5.Some early models (pre Serial No 600001 were susceptible to damage in transit(fluxgate sensor springing free from gimbal assembly). If received for service theseunits should be modified using the gimbal support bracket (see section 4).2. Functional TestDisconnect the Fluxgate from the autopilot and check continuity as follows:-Cable Colour Connector pin no ResistanceScreen to Blue 2/4 < 10 ohmsRed to Green 3/5 < 5 ohmsRed to Yellow 3/6 < 5 ohmsRed to Screen 3/2 Open circuit3. Magnetic DeviationThe Z130 Fluxgate Compass requires careful siting if optimum autopilot performanceis to be achieved. The SeaTalk Course Computers are able to correct the compassfor any deviating magnetic fields present when the linearisation procedure is carriedout. Any further deviation, introduced after linearisation, will introduce an error betweenthe Fluxgate and the ships compass. This can be removed by carrying out thelinearisation procedure again. If the displayed deviation is greater than +/-15 degreesthe Fluxgate should be re-sited.Note:The linearisation procedure should always be carried out if the fluxgate has beenexchanged, removed or moved from its original mounting position.SeaTalk Service Manual 3

AutohelmZ130 Fluxgate General Assembly4SeaTalk Service Manual

Autohelm4. Gimbal Support Bracket installation (Spares Kit M096)This kit comprises of a back case, cable assembly, pivot blocks, support bracket andpivot retaining screws.1. Remove the four case screws and take off the front cover and seal.2. Carefully remove the flexible circuit from the connector in the rear moulding.3. Remove and discard the pivot block mounting screws and lift away fhe fluxgateassembly.4. Build the Fluxgate assembly into the new back case as shown in fig. 1. Use thenew screws supplied to retain the pivot mounting blocks and support bracket. Useonly hand screw drivers for re-assembly to ensure screws are not over tightened.Rotate screws anticlockwise to locate in the thread before tightening.5. Carefully insert the flexible circuit tail into the connector in the rear moulding.Ensure the tail is not twisted and passes over the support bracket (see fig. 1.)6. Before installing the cover check the gimbal action of the new assembly by tiltingthe case in all directions and observing the fluxgate movement.7. Refit the front cover and seal (again rotating the screws anticlockwise to locate andtightening with a hand screw driver).8. Functionally check the Fluxgate with a D.V.M. as follows:Cable Colour Connector Pin no. ResistanceScreen to Blue 2/4

Autohelm6. Before installing the cover check the gymballing action of the new assembly bytilting the case in all directions and observing the fluxgate movement.7. Refit the front cover and seal (again rotating the screws anticlockwise to locate andtightening with a hand screw driver).8. Functionally check the Fluxgate with a D.V.M. as follows:Cable Colour Connector Pin no ResistanceScreen to Blue 2/4

6. Product history - Fluxgate Compass (Z130)Change Serial No CommentsProduction Start 400001Gimbal Supportbracket addedAutohelm600001 Reduces risk of fluxgate assemblybecoming dislodged during transit.7. Spares Numbers - Fluxgate Compass (Z130)Item Catalogue No. CommentsFluxgate bobbin & M022Includes inner gimbal sub-assembly and 2 xGimbal Assemblypivot assemblies.Support bracket M096 Includes back case cable assembly pivotblocks, support bracket and pivot retainingscrews, (fitted as standard to units built afterSerial No 600001.SeaTalk Service Manual 7


AutohelmFluxgate Compass (Z105)SeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Functional Test 33. Magnetic Deviation 32SeaTalk Service Manual

AutohelmFluxgate Compass (Z105)1. DescriptionThe Z105 Fluxgate Compass Transducer contains a precision Fluxgate sensor and,once detected as faulty, should be replaced as a complete unit.2. Functional TestDisconnect the Fluxgate from the autopilot and check continuity as follows:-Cable ColourScreen to BlueRed to GreenRed to YellowRed to ScreenResistance< 10 ohms< 5 ohms< 5 ohmsOpen Circuit3. Magnetic DeviationThe Z105 Fluxgate Compass requires careful siting if optimum autopilot performanceis to be achieved. The SeaTalk Course Computers are able to correct the compassfor any deviating magnetic fields present when the linearisation procedure is carriedout. Any further deviation, introduced after linearisation, will introduce an error betweenthe Fluxgate and the ships compass. This can be removed by carrying out thelinearisation procedure again. If the displayed deviation is greater than +/-15 degreesthe Fluxgate should be re-sited. Note:The linearisation procedure should always be carried out if the fluxgate has beenexchanged, removed or moved from its original mounting position.SeaTalk Service Manual 3


AutohelmRudder Reference Transducer (Z060)SeaTalk Service Manual 1

AutohelmContentsPage1. Description and Functional Test 32. Resetting Centre Position 33. Product History 7IllustrationsFig. 1. Rudder Reference Unit Standard Installation 5Fig. 2. Adjusting Centre Position 62SeaTalk Service Manual

Autohelm1. Description and Functional TestThe rudder reference transducer contains a single turn plastic potentiometer toprovide the course computer with rudder position information.With the rudder reference transducer disconnected from the connector unit, itsoperation can be checked as follows:-a) Connect an Ohmeter across the blue and red wires.b) Position the rudder reference transducer arm diametrically opposite the cablegland and check the reading is between 2.2 and 2.8K ohm.c) Slowly rotate the arm in both directions and check that the resistance increasesand decreases smoothly according to arm movement.A faulty rudder reference transducer is replaced as a complete unit.2. Resetting Centre PositionIt is important that the rudder reference transducer is correctly centred to ensure thatthe potentiometer output remains within the working range of the Analogue to Digitalconverter (1.0V to 4.0V). During assembly, the unit is set up to ensure that when therudder reference transducer arm is diametrically opposite the cable gland, the wiperis at its mid position. The installation instructions then direct the installer to mount thetransducer so that with the rudder amidships the arm is diametrically opposite thecable gland (see figure 31). Should it be necessary to install the transducer with itsarm in an alternative position to the cable gland, the centre position of thepotentiometer must be reset as follows (see figure 32).1. When the rudder is amidships, determine the orientation of the rudder referencetransducer arm to the cable gland.2. Remove the plastic base plug from the underside of the transducer and connect anohmeter across the red and blue wires.3. Remove the plastic cap from the top of the unit to gain access to the locking nut ofthe taper collet.4. Slacken the locking nut until the potentiometer shaft can be turned within therudder reference transducer cap.5. Position the arm as determined in 1. and rotate the potentiometer shaft with ascrewdriver until the meter reads between 2.4 and 2.6k ohm.6. While pressing the potentiometer and potentiometer mounting plate into the rudderreference transducer body, tighten the locking nut to clamp the potentiometer shaft tothe cap.7. Confirm the meter still reads between 2.4 and 2.6k ohm.8. Check that the total vertical movement at the end of the transducer arm is lessthan 1.5mm. If it is greater, steps 4. to 8. must be repeated ensuring that thepotentiometer and mounting plate are fully pressed into the transducer body.9. Finally, replace the plastic plug into the base and the cap into the tap.SeaTalk Service Manual 3

AutohelmFig. 1. Rudder Reference Unit Standard Installation4SeaTalk Service Manual

AutohelmFig. 2. Adjusting Centre PositionSeaTalk Service Manual 5

Autohelm3. Product History Rudder Reference (Z060)ChangeSerial NumberSlotted mounting holes introduced 980001Stainless Steel fittings introduced 290001Stainless Steel studding introducedK900016SeaTalk Service Manual

AutohelmPushpit Windvane Transducer (Z087)Masthead Windvane Transducer (Z080)Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. Description 32. Functional Test (Z080 Masthead Transducer) 33. Functional Test (Z087) Pushpit Transducer) 34. Product History 45. Spares Numbers 4IllustrationsFig. 1. Z080 Masthead General Assembly 5Fig. 2. Z080 Mount Assembly 62SeaTalk Service Manual

Autohelm1. DescriptionThe Z080 and Z087 Windvane transducers are only compatible with AutohelmSeatalk products. The push pit transducer (2087) is identical to the Vane transducerin the Masthead Unit (Z080). When connecting a masthead Transducer (Z080) to anAutohelm ST7000 Autopilot do not connect the yellow core into the Aux 1 connectorin the connector box. Simply connect the other four cores and trim the yellow backshort.2. Functional Test (Z080 Masthead Transducer)The operation of the Z080 masthead mounted windvane can be checked using thefollowing procedure:-1. Connect +8V dc to the red core and 0V to the screen.2. Connect a digital volt meter across the screen and the green core.3. Rotate vane head through 360 degrees and check that the meter reading oscillatessinusoidally. The maximum reading must be between 6V and 5.5V. The minimumreading must be between 2V and 2.5V.4. Repeat section 3 with the meter connected across the blue core and screen.The anemometer transducer can not easily be tested and a replacement pod shouldbe fitted if suspected faulty.3. Functional Test (Z087 Pushpit transducer)The pushpit vane transducer can be functionally checked by following the Mastheadtest procedure.SeaTalk Service Manual 3

Autohelm4. Product History (Z080 Masthead Transducer)Change Serial No. CommentsProduction Start 590001Drain hole added to anemometerbossConnector housing lengthincreasedSelf cut grub screws replace brassinserts in vane and anemometerbossesK90001K90164L90000Allows mast arm assembly to belocated tighter onto mast socketTighter location of vane and cupsonto respective transducer shafts5. Spares Numbers (Z080 Masthead Transducer)Item Catalogue No. CommentsVane transducer pod Q001 Used on both Z080 and Z087transducersAnemometer transducer pod Q002Masthead transducer arm Q025 Mast arm and pod housingwithout transducer podsMasthead socket and cableQ026Vane and CupsD1394SeaTalk Service Manual

AutohelmZ080 Masthead Transducer General AssemblySeaTalk Service Manual 5

AutohelmZ050 Mount Assembly6SeaTalk Service Manual

AutohelmLinear Drive UnitsService ProceduresLinear Drive Unit (Z029, Z032)Linear Drive Unit (Z029, Z058, Z059)SeaTalk Service Manual 1

AutohelmContentsPage1. Linear Drive Unit Introduction 32. Inspection 33. Dismantling 34. Re-assembly 45. Operation with non Autohelm Autopilots (24V systems) 46. Functional Test 47. Product History (Type 2 Long Stroke) 88. Product History (Type 1) 89. Product History (Type 2 Short Stroke) 810. Spares Numbers 9IllustrationsFig. 1. General Assembly 72SeaTalk Service Manual

Autohelm1. Linear Drive UnitThe linear drive unit comprises a belt drive reduction stage from the motor, a singleepicyclic gearbox and a two start recirculating-ballscrew to provide linear motion. Anelectromagnetic clutch locks the outer ring of the epicyclic gearbox when drive isrequired. The drive is unique in providing efficient drive combined with very smoothbackdrive at extremely low loads.2. InspectionBefore stripping down or testing the drive unit, a close visual inspection should bemade to establish if the cause of the problem is external.Poor mechanical installation where the unit can foul obstructions, particularly at theend of stroke, can distort the drive module and lead to rough operation and highbackdrive loads. The drive module is assembled at Nautech in a dirt free environmentto precise limits. If disturbed, rough operation and high backdrive loads will result.3. DismantlingAfter removing the unit from the boat and to gain access to drive motor, drive belt,clutch rotor or drive module the following steps apply:a) Unscrew and remove the two caphead screws which secure the plastic dust coverto the main unit (use 'M3' alien key). Slide the dust cover off the girdle tube.b) Unscrew and remove the four M6 caphead screws with washers and the two longhexagonal studs at the centre-sides of the master plate. Separate the mounting coverassembly from the master plate assembly, after feeding the cables through thegrommet.c) If servicing the clutch rotor assembly, remove it from the mounting plate byunscrewing the central caphead screw which secures the assembly to the casting.Note that the assembly is sprung loaded and care should be taken when removing.d) If replacing the drive belt, loosen the three M6 caphead screws with washerswhich secure the motor to the masterplate. With the tension taken off the belt it canbe slipped off both pulleys.e) If replacing the drive motor unscrew and remove the three M6 caphead screws asabove and take the weight of the motor as it is released. Note that the power cablesare extended and passed through grommets in the masterplate. Remove the drivebelt.f) If servicing the drive module, follow steps a) b) d) and e) above. Then remove thecirclip at the front of the clutch plate/ring gear assembly and withdraw the assembly.Locate the leadscrew journal and carrier on a firm block to prevent bending thejournal and drive out the roll pin securing the carrier to the leadscrew (generalassembly).SeaTalk Service Manual 3

AutohelmSlide off the carrier assembly and the four planet gears. Finally withdraw the drivenpulley assembly from the drive module.4. Re-assemblyIn all cases rebuilding the unit is a straight reversal of the above procedures, but thefollowing points should be noted:-a) If replacing a drive motor, first ensure that the drive pulley is fitted in the correctorientation (general assembly). Ensure that the motor spindle is degreased and driedthoroughly before bonding the pulley to the shaft with Loctite 601 or equivalentanaerobic adhesive. After bonding, the unit should not be put under power for at leastone hour.b) If replacing the clutch rotor assembly, ensure the rotor can be pulled forward alongthe two dowels against the spring and when released returns hard against themounting cover. If this is not done, the assembly will jam the drive train when the unitis rebuilt. Also after the unit is completely rebuilt check for a metallic click when theclutch voltage is applied and removed showing the clutch is operating correctly.c) When rebuilding from the drive module stage, ensure that the driven pulley, planetgears, washers and carrier are all correctly located and turning freely before and afterthe roll pin securing the carrier to the leadscrew is refitted. Note that extreme caremust be taken to fully support the leadscrew journal when driving the roll pin backinto the carrier. This prevents the leadscrew journal from being bent. Check for freemovements of the ram tube in and out before proceeding further. When refitting theclutch plate assembly ensure that it is engaged correctly with the planet gears beforerefitting the washer and circlip. Check again for free ram tube movement beforerefitting the mounting cover.d) Ensure that all cables are correctly routed, secured and pulled through away frommoving parts.e) Check the correct length drive module, drive motor and product label have beenused.5. Operation with non Autohelm Autopilots (24v systems)It should be noted that the 24V version of the Autohelm linear drive requires a 12Vclutch signal. If used with other manufacturers autopilots, steps should be taken tolimit the voltage supplied to the clutch.6. Functional TestHaving reassembled the drive unit the following functional test (Fig.2) must becompleted.4SeaTalk Service Manual

Linear Drive Unit - Functional Test Procedure (Z029, Z032, Z039, Z085, Z059)AutohelmSeaTalk Service Manual 5

Autohelm* No load current limits :- Minimum (A) Maximum (A)Type 1 (Z039) 2.0 3.0Type 2 12V (Z029, Z058) 2.5 3.5Type 2 24V (Z032, Z059) 1.0 2.56SeaTalk Service Manual

Fig. 1. Linear Drive Unit (Z029, Z032, Z039, Z058, Z059) General AssemblyAutohelmSeaTalk Service Manual 7

Autohelm7. Product History Type 2 Linear Drive Actuators (LongStroke) (Z029 & Z032)ChangeSerial Number CommentsIntroduction 470001Fracmo Motors780042introducedGirdle Buffer/Stopmaterial changedRockford Leadscrewintroduced790045 Extended high temperature use causedrubber buffer to swell giving higher backdrive1000028. Product History Type 1 Linear Drive Actuators (Z039)Change Serial Number CommentsIntroduction 470003Fracmo Motors680086introducedGirdle Buffer/Stopmaterial changedRockford Leadscrewintroduced790068 Extended high temperature usecaused rubber buffer to swell givinghigher back drive1000029. Product History Type 2 Linear Drive Actuators (ShortStroke) (Z058 & Z059)Change Serial No. CommentsIntroduction 470001Fracmo Motors introduced 780042Girdle Buffer/Stop material 790045changedRockford Leadscrewintroduced100002 Extended high temperature use causedrubber to swell giving higher backdrive.8SeaTalk Service Manual

Autohelm10. Spares Numbers - Linear Drive Unites (Z029, Z032, Z039Z058 & Z059)ItemDrive Motor (Z039)Drive Motor (Z058 & Z029)Drive Motor (Z032 & Z059)Short Stroke drive moduleLong Stroke drive moduleDrive BeltClutch/RotorCatalogue No.N001N002N003N004N005N006N007SeaTalk Service Manual 9


AutohelmRotary Drive Units (Z028, Z031 & Z037)SeaTalk Service Manual 1

AutohelmContentsPage1. Rotary Drive Unit Introduction 32. Dismantling 33. Re-assembly 34. Operation with non Autohelm Autopilots (24V) 45. Functional Test 46. Spares Numbers 7IllustrationsFig. 1. General Assembly 62SeaTalk Service Manual

Autohelm1. Rotary Drive UnitThe rotary drive unit comprises a belt drive reduction stage from the motor, and a twostage epicyclic gearbox. An electro-magnetic clutch locks the outer ring of the firststage gearbox when drive is required. This arrangement provides very quietoperation with low backdrive torques.2. DismantlingAfter removing the unit from the boat and to gain access for drive motor, drive belt orclutch replacement, the following steps apply:-a) Unscrew and remove two caphead screws using M3 alien key. These screwssecure the plastic cover to the main unit. Ease the power supply and clutch cablesthrough the grommet whilst removing the plastic cover and finally remove the coveraltogether.b) If servicing the clutch assembly remove the dust cover as above then unscrew andremove the two caphead screws which secure the clutch rotor and plate assembly tothe two pillars holding it off the main assembly (use a M3 alien key).c) The clutch rotor is fixed to its plate by one caphead screw through the centre whichis spring loaded. Therefore, care should be taken to hold the clutch rotor as the screwis removed.d) If servicing the drive motor assembly, remove the dust cover as above thenunscrew and remove the 4 x 6mm caphead screws with washers and also the twolong hexagonal studs at the centre sides of the main assembly. The mounting coverassembly can now be removed from the master plate. Care must be taken whenremoving the cover assembly to ensure the drive gear disengages without damage.This is best done with the mounting cover placed down on the bench and the drivemotor facing uppermost so that the planet gears within the mounting cover will stay inplace. If they become dislodged keep them safely ready for reassembly.e) Support the motor, unscrew and remove the three M6 caphead screws andwashers securing the motor to the master plate and slip the drive belt off the pulley.f) If replacing the drive belt it will only be necessary to loosen the three screws thatsecure the motor to take the tension off the belt whilst it is slipped off both pulleys.3. ReassemblyIn all cases rebuilding the unit is a straight reversal of the above procedures, but thefollowing points should be noted:-a) When refitting a drive motor ensure that the drivepulley is fitted to the motor shaft in the correct orientation (general assembly). Notealso that the motor shaft should be degreased with a suitable solvent and dried offthoroughly before bonding the pulley in place using Loctite 601 or equivalentanaerobic adhesive. Following bonding the unit should not be placed under full powerfor at least one hour.SeaTalk Service Manual 3

Autohelmb) When rebuilding the clutch rotor and plate assembly ensure the rotor can be pulledforward along the two dowels against the spring and when released it returns hardagainst the mounting plate. If this is not done, the assembly will jam the drive trainwhen the unit is rebuilt. Also, check it pulls in and releases when a voltage is appliedand removed.c) When refitting the mounting cover to master plate assembly, firstly ensure that allfour planet gears are correctly fitted and freely rotate when the drive shaft is rotated.Secondly, when lowering the master plate onto the mounting cover it will help tolocate the gear train if the drive shaft is rotated slightly to engage the geared shaftwith the planet gears. Ensure the drive train rotates freely before refitting andtightening all the screws.d) When refitting the dust cover ensure that all leads are either secured to thehexagonal pillars or pulled uptight through the grommet so that they are kept clear ofany moving parts.e) Ensure that the correct drive motor (and product label) is fitted by a simple voltageand current test checked against the serial number.4. Operation with non Autohelm Autopilots (24v systems)It should be noted that the 24V version of the Autohelm rotary drive requires a 12Vclutch signal. If used with other manufacturers autopilots, steps should be taken tolimit the voltage supplied to the clutch.5. Functional TestHaving reassembled the drive unit, the following functional test (Fig.2) must becompleted.Without stalling the output shaft it is impossible to check for clutch slip and so caremust be taken when handling the drive unit to ensure that no grease is allowed ontothe clutch surfaces.4SeaTalk Service Manual

AutohelmRotary Drive Unit - Functional Test Procedure (Z028, Z031, Z038)*No load current limits:- Minimum (A) Maximum (A)Type 1 (Z037) 2.0 3.0Type 2 12V (Z028) 2.5 3.5Type 2 24V (Z031) 1.0 2.5SeaTalk Service Manual 5


Autohelm6. Spares numbers - Rotary Drive Units (Z028, Z031, Z037)ItemDrive Motor (Z037)Drive Motor (Z028)Drive Motor (Z031)Drive BeltClutch/RotorCatalogue No.N001N002N003N006N007SeaTalk Service Manual 7


AutohelmHydraulic Drive Units Service ProceduresType '0' Piston Pump (Z081)Constant Running Power Pack (Z064, Z065, Z066, Z067)Reversing Gear Pump (Z030, Z033, Z041)SeaTalk Service Manual 1

AutohelmContentsPage1. Hydraulic Drive Units Introduction 32. Constant Running Power Pack (Z064/65/66/67) 32.1 Dismantling and Re-assembly 33. Reversing Gear Pumps (Z030/33/41) 64. Type '0' Piston Pump (Z081) 84.1 Type '0' Pump Re-installation 84.2 Type '0' Pump Bleeding 8IllustrationsFig. 1. Constant Running Power Pack General Assembly 5Fig. 2. Reversing Gear Pump General Assembly 7Fig. 3. Type '0' Pump Bleeding 92SeaTalk Service Manual

Autohelm1. Hydraulic Drive UnitsThree types of hydraulic drive units are covered, the constant running power pack,the reversing gear pumps and the type '0' piston pump. The most common cause ofproblems is trapped dirt in the valve assemblies between the balls and their seats.This provides a short circuit path for the oil, which will greatly reduce the pressuregenerated to move the steering cylinder. It is important to observe absolutecleanliness at all times during dismantling and reassembly. If it is necessary toservice the drive units when installed the following points should be observed:-- Hydraulic pressurised systems must be depressurised before work is started.- The drive unit should be isolated from the main steering system to minimise fluidloss.2. Constant Running Power Pack (Z064, Z065, Z066, Z067)The constant running hydraulic power pack provides a drive unit for larger vesselswith steering cylinder displacements above 400cc. The power pack motor is switchedindependently of the autopilot and runs continuously. When rudder movement isrequired, the solenoid valves are energised by the course computer to direct the flowto the steering cylinder.The servicing information allows replacement of the solenoid valve assembly,inspection and cleaning of the check valve and relief valve assembly and sealreplacement. It is not possible to service the pump and filter assembly which arecontained within the reservoir as the reservoir seal requires special assemblytechniques.2.1 Dismantling and Reassemblya) To remove the solenoid valve, undo the four caphead bolts securing it to themanifold. Remove the valve carefully to ensure the 0 ring seals are not lost.Reassembly is a simple reversal of this procedure.b) To clean the check valve assembly, unscrew the cartridge and remove it alongwith the washer and 0 ring seal. The spring and ball can then be taken out. The seatand 0 ring will probably remain in position and oil from the reservoir is likely to washout any dirt that could have been causing problems. If the check valve assembly isfurther dismantled, care must be taken when reassembling to prevent damage to the0 rings. The best method is to place the 5/ Sin. 0 ring and seat in the manifold andscrew in the cartridge (without the ball or spring) to position the seat within its sealingring. The cartridge can then be removed and the ball and spring positioned within thecartridge. Some grease may be used to retain them whilst the cartridge with its 0 ringand washer is screwed into position.SeaTalk Service Manual 3

Autohelmc) If the relief valve assembly is removed, the relief valve setting should be checkedafter reassembly. The factory pre-set is 750 psi.d) Ensure all parts are reassembled in the current sequence and nothing is missedout during reassembly.4SeaTalk Service Manual

AutohelmFig. 1.Z064/6 5/66/67 –Constant Running Power Packs –Pilot Check and Relief ValveGeneral AssemblySeaTalk Service Manual 5

Autohelm3. Reversing Gear Pumps (Z030f Z033, Z041)Reversing Gear Pumps are fitted with a single check valve assembly which allowsoperation with unbalanced rams.To clean the valve assemblies, it is usually only necessary to remove the cap, springand ball. The dirt will in most cases be washed out with oil from the reservoir.If the seats and 0 ring seals are removed, these are best replaced by using the cap(without the spring) to position them. The cap may then be removed, andreassembled with the spring in position. Ensure all parts are reassembled in thecorrect sequence and nothing is missed out.6SeaTalk Service Manual

AutohelmFig. 2. Z041, Z030, Z033 - Reversing Gear PumpSeaTalk Service Manual 7

Autohelm4. Type'0'Piston Pump (Z081)A faulty type '0' pump should be replaced as a complete item. Care should be takenwhen removing the pump, not to introduce any dirt into the hydraulic system.The type '0' pump is sensitive to trapped air and care should be taken to remove itduring installation and commissioning.4.1 Type '0' Pump ReinstallationWhen a faulty pump is replaced new sealing washers should always be installedbetween the fittings and the pump body. Connect the reservoir line to the pumpleaving the two drive pipes disconnected at points A and B (Fig.3). Temporarily blankoff the two tee unions to the steering system to avoid fluid loss. The pump shouldthen be bled using the following procedures:-1. Fill pipe B with oil.2. Connect pump drive cable to a 12V dc supply via a 10 ohm 50W resistor. Thisallows the pump to rotate slowly without cavitating.3. Continue adding oil to pipe B as the level drops. Note: If oil is expelled from pipe Bthen reverse the connections to the pump.4. Stop the pump when oil appears out of pipe A. Reconnect A to the steering systemand repeat steps 2 and 3 until the steering ram moves.5. Observe the movement of the ram and turn the helm pump in the oppositedirection to keep the rudder stationary. This will cause any remaining air in pipe A tobe drawn up to the helm pump and vented.6. When all the air in pipe A is cleared stop the pump and reconnect pipe B to thesteering system.7. Reverse the polarity of the pump and repeat from section 5.Note: This type of positive displacement pump is sensitive to trapped air. It should bethoroughly bled before using the autopilot.8SeaTalk Service Manual

AutohelmFig. 3. Type '0' Piston Pump BleedingSeaTalk Service Manual 9


AutohelmInboard/Outboard Drive Unit (Z088)Service ProceduresSeaTalk Service Manual 1

AutohelmContentsPage1. I/O Drive Unit Introduction 32. Motor Replacement 32.1 Dismantling 32.2 Re-assembly 33. Functional Test 44. Spares Numbers 6IllustrationsFig. 1. General Assembly 52SeaTalk Service Manual

AutohelmFig. 1. I/O Drive Unit - Exploded View (Z088)SeaTalk Service Manual 3

Autohelm4. Spares numbers - I/O Sterndrive Unit (Z088)ItemDrive MotorDrive AssemblyMercruiser Installation KitVolvo Installation KitCatalogue No.N017N018D137D1294SeaTalk Service Manual

Autohelm1. I/O Drive UnitThe I/O drive unit comprises a motor with a two-stage spur reduction gearbox.A single toothed clutch transmits the torque to a recirculating ball screw. The clutch isheld apart by a small spring to ensure the clutch tooth does not 'ratchet1 whendisengaged. The I/O drive unit may be used with all 610 versions of the AH6000power pilot and both theSeaTalk ST6000 and ST7000 Autopilots.Servicing is restricted to motor replacement.Great care must be taken when servicing to ensure all screws are fully tightened. TheI/O Drive Unit is subjected to high vibration levels and loose screws will quickly workfree.2. Motor Replacement (No 17)2.1 Dismantling- Unscrew the 2 off rear dust cover retaining screws and remove the dust cover.- Unscrew the 4 off support plate retaining screws complete with washers.- Carefully remove the support plate sub-assembly complete with Idler gear subassemblyand 2 off spacers. Ensure that the support plate is held square duringremoval to prevent damage to clutch shaft. It is now possible to remove theclutch/gear core sub-assembly, spring and plastic bearing from clutch shaft.- Undo the lock nut of the 4 pin connector and remove.- Unscrew 2 off front dust cover retaining screws and push connector out of front dustcover.- Slide dust cover along girdle tube sub-assembly to provide access to motor subassemblyNo. 17.- Desolder the wires from the motor.- Unscrew the 2 off motor retaining screws complete with washers and remove. Pullmotor away from master plate sub-assembly.2.2 Reassembly-Assemble motor sub-assembly (No.17) to master plate sub-assembly and securewith 2 off screws complete with washers. (Fully tighten).- Solder the wires to the new motor.- Assemble connector to front dust cover and secure with lock nut.- Slide dust cover along girdle tube and assemble to master plate.Check that the motor and clutch leads are not trapped during assembly.- Fully tighten the 2 off screws to secure dust cover.- Reassemble the plastic bearing spring and clutch (gear) core sub-assembly toclutch shaft.- Assemble the Idler gear sub-assembly complete with 2 off washers to support platesub-assembly.SeaTalk Service Manual 5

Autohelm- Position the support plate sub-assembly on clutch shaft and ensure Idler shaft andsupport plate pillars engage correctly, the support plate must be held square duringassembly to prevent damage to the clutch shaft.- Fully tighten the 4 off screws complete with washers to secure support plate.- Assemble rear dust cover to master plate sub-assembly and fully tighten the 2 offsecuring screws.3. Functional TestIt is important to check the clutch operation to make sure it will disengage even underload. Failure of the clutch to disengage is probably \ due to a damaged clutchtooth in which case the drive unit must be replaced.The spur reduction gearbox is noisy compared to the epicyclic gearboxes on otherdrive units. This is normal. The no load motor running current with the clutch engagedshould be less than 1.5A.The clutch current at 10V should be between 0.7 and 10A. Connect the drive unit toan ST7000 system and switch on power. Set rudder gain to maximum.- Press 'Auto'- Press '+10' 7 times to drive the unit fully out.- Check that clutch holds on end stops without any ratcheting.- Press 'Standby'- Check that clutch disengages.- Press 'Auto'- Press -10 7 times to drive unit fully in.- Check that clutch holds.- Press 'Standby'- Check that clutch disengages.6SeaTalk Service Manual

Autohelm Inboard Autopilots (ST6000 and ST7000 systems) Service ...

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