Nexus AUTOPILOT Installation And Operation Manual Download | Manualshive

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9 Installation

9.1 Installation general

Reliable and accurate operation of an Autopilot depends more on correct installation than
any other piece of marine electronics. Please read and fully understand the installation
requirements before attempting installation.

Note! If in doubt, obtain the services of an experienced Autopilot installation
technician.

•

The installation includes 8 major steps:

1.  Read the installation and operation manual.
2.  Plan where to install the different parts.
3.  Make the attachments needed for Pumpset and Cylinder and install them.
4.  Run the cables.
5.  Install the transducers and instruments.
6.  Take a break and admire your installation.
7.  Learn the functions and calibrate your systems.
8.  Make the Dockside Testing before the Sea Trials.

Before you begin drilling ...

think about how you can make the installation as neat and

simple as your boat will allow. Plan where to position the transducer and the instrument.
Think about leaving space for additional instruments to be fitted in the future.

A few "do nots" you should consider:

•

Do not cut the cables too short. Allow extra cable length at the instrument so it can be

disconnected for inspection without having to disconnect all attached cables.

•

Do not place sealant behind the instrument. The gasket eliminates the need for sealant.

•

Do not run cables in the bilge, where water may accumulate.

•

Do not run cables close to fluorescent light sources, engine or radio transmitting

equipment, in order to avoid possible electrical disturbances.

•

Do not rush, take your time. A neat installation is easy to do.

The following material is needed:

•

Wire cutters and strippers

•

A pair of flat pliers

•

Small and large Philips and flat head screw driver

•

Hole saw for the instrument clearance hole 50 mm (2”)

•

Drill for the mounting holes (2,8 mm 0,11” for the instrument)

•

Cable ties

INSTALLATION

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Summary of Contents for AUTOPILOT

Page 1: ...0 Installation and Operation Manual ...

Page 2: ...topilot instrument Art No 20445 5 for version 1 12 Nexus Servo Unit A 1500 version Art No 21035 for version 2 23 Nexus Servo Unit A 1510 version Art No 21035 2 for version 2 23 Nexus Rudder Angle Transmitter Art No 21036 Edition June 2000 ...

Page 3: ... 9 3 1 3 Instrument modes 9 3 1 4 Instrument power on off 9 3 2 How to use the push buttons 10 3 2 1 MODE 10 3 2 2 LEFT 10 3 2 3 RIGHT 10 3 2 4 KEY 10 3 2 5 Clear 10 3 2 6 Setup mode 10 3 2 7 Lighting 10 4 Function 12 4 1 Standby mode 12 4 2 Autopilot mode 12 4 2 1 Activate automatic steering 12 4 2 2 Turn off automatic steering 12 4 2 3 Automatic steering by compass 12 4 2 4 Automatic steering by...

Page 4: ...tion VAR 21 5 5 4 C3 Auto deviation Auto DEV 21 5 5 5 C4 Check auto deviation Auto CHK 22 5 5 6 C5 Clear auto deviation Auto CLR 22 5 5 7 C6 Adjust compass alignment ADJ 22 6 Maintenance 23 6 1 Instrument maintenance 23 6 2 Drive unit maintenance and inspection schedule 23 7 Fault finding 24 7 1 General 24 7 2 Symptom Cause Action 24 7 3 Nexus Network error messages with cause and remedy 27 8 Spec...

Page 5: ... 46 11 Sea Trials 47 11 1 Preparations 47 11 2 Compass calibration 47 11 3 Automatic Pilot Calibration APC 47 12 Fine tuning 48 Operator Warning An Autopilot is an aid to navigation only It is not intended or designed to replace the man on watch Always be in position to monitor the boat s heading and to watch for navigational hazards Be prepared to revert to manual steering immediately if an undes...

Page 6: ... other Nexus digital and analog instruments The Autopilot Servo Unit A 1500 is designed for sailing and power boats from 35 ft 11 m to over 160 ft 50 m depending on drive units used Hydraulic drive units provide precise control with low power consumption Connection can also be made to solenoid valves of electro hydraulic steering systems allowing use on very large boats Hydraulic linear drives pro...

Page 7: ...information direct from an electronic compass or gyro compass A 1500 only wind transducer navigators and compares this against the course set by the instrument and rudder 1 4 3 Rudder Angle Transmitter The Rudder Angle Transmitter provides the Autopilot with accurate rudder position information It is mounted near the rudder shaft and connected to the tiller arm or quadrant with an adjustable ball ...

Page 8: ...oof of purchase Also your details are added to our customer database so that you automatically receive new product catalogues when they are released 1 6 About this manual Each time a push button is referred to in this manual the push button name will appear in bold and CAPITAL letters e g MODE Unless otherwise stated the push button presses are momentary Each time a function is mentioned in the te...

Page 9: ... and the same order they will be addressed by the Remote Control instrument if used The example shows that the instrument version number is 1 6 and the logical ID number given is 17 Warning Do not activate any Autopilot functions until Dockside Testing and Sea Trials APC routine have been performed 2 2 Re initialising the instrument If two instruments have been given the same ID number by mistake ...

Page 10: ...w at top of the dis play 3 1 3 Instrument modes Standby mode The instrument functions as a passive compass re peater Autopilot mode When any Autopilot function is activated Setup mode It allows calibrating your Network settings Edit mode It allows editing settings when digits are flashing 3 1 4 Instrument power on off You will switch on off your Nexus instruments by using the instrument switch on ...

Page 11: ... edit mode a press on RIGHT increases a digit by one 3 2 4 KEY A press on KEY activates the Autopilot in selected steering function A second press on KEY turns off the Autopilot The text OFF is printed above KEY which also is coloured red In setup mode a press on KEY unlocks a digit to access edit mode When unlocked the digits are active flashes and can be edited by pressing LEFT RIGHT and MODE as...

Page 12: ... the display will be lit momentarily To select between the 4 light levels LOW MID MAX and OFF press RIGHT To lock the selected level press KEY The selected light level will be copied to all Nexus instruments con nected to the Network It is not possible to reduce or turn off the lighting on an individual instrument OPERATION ...

Page 13: ...ction is activated The function text at lower line to the right confirms which steering function is activated ex HDG for compass steering Note If a page is not available such as when no waypoint information is programmed activated or no navigator or wind transducer con nected the page arrow will not stop at that page 4 2 2 Turn off automatic steering To turn off automatic steering press KEY The te...

Page 14: ...rse when the next waypoint information is displayed and the helmsman should ensure that there are no boats or other hazards on the new course as the waypoint is changing When using waypoint sequencing in a route list it is extremely important that the helmsman is at the steering position and ready to override the pilot if the course change would cause collision with other boats or objects Set all ...

Page 15: ... LEFT To steer to starboard press RIGHT A short press changes the value by 1 a long press by 10 When making large changes of over 30 it may take about 1 minute for an accurate course to be re established due to changes in boat balance which must be recognised by the automatic trim function To tack press RIGHT and LEFT together and the boat will come about the same apparent wind angle on the opposi...

Page 16: ...T and hold it until the desired rudder angle is displayed To change the rudder angle to port press LEFT and hold it until the de sired rudder angle is displayed 4 2 7 Dodging and returning to last automatic steering function To dodge turn off the automatic steering by pressing KEY and dodge manually If you want to re activate the last steering function and value press MODE and KEY together within ...

Page 17: ...o change a setting To unlock a setting press KEY To change a setting press LEFT RIGHT and MODE as required To lock a setting press KEY 5 1 4 How to return to previous mode To return to previous mode press KEY when the text return RET is displayed 5 1 5 Factory default settings After each setting we have listed the factory default settings This allows you to manually get back to factory default set...

Page 18: ...o select the lighting level indi vidually for single instruments 5 3 Autopilot setup group P 5 3 1 P0 Return RET To return to previous mode press KEY when the text RET is dis played 5 3 2 P1 Rudder RUD Possible settings are 0 Minimum to 9 Maximum Set by the APC routine The setting affects the degree of rudder angle used The most critical adjustment for good steering is the rudder Too high a settin...

Page 19: ...a provide initially high rudder control when making a large course change and to deceler ate the swing of the bow as a boat approaches the desired course Course holding with heavy and difficult to steer boats is greatly im proved when using this feature Too little counter rudder will allow the boat to overshoot on large course changes Too much will cause un necessary rudder corrections and a tende...

Page 20: ... reserved for future functions 5 3 8 P7 Automatic Pilot Calibration APC Possible settings are ON or OFF The APC routine automatically sets RUD SEA CRD ATC and RRS The Autopilot will not function unless the boat pass the APC routine The APC will automatically determine and correct how wires and pipes are connected It will also learn how the boat reacts on different rudder commands and automatically...

Page 21: ... person on watch To confirm and restart the timer press any push button If not con firmed within 1 minute the optional external alarm buzzer if connected to the Nexus Server will sound for 1 minute to alert the rest of the crew 5 4 4 A3 Cross Track Error alarm XTA Possible settings are 0 00 OFF to 9 99 Default setting is 0 00 This function is only available in NAV function when the Autopilot is co...

Page 22: ...ally correct the deviation of your compass Take the boat into a slow turn in calm sea and away from other boats or obstructions There is no need to perform a perfect circle When steady select C3 Auto DEV and press KEY to start The pres ent uncorrected compass heading is displayed and the compass auto deviation is in progress Turn the boat in a 1 circle and when ready press KEY again If successful ...

Page 23: ...was too great to be ac cepted Make a new auto deviation check and if you still get ERR 19 make a new auto deviation since the last one was probably disturbed 5 5 6 C5 Clear auto deviation Auto CLR To clear the calibration created by the auto deviation select C5 Auto CLR and press KEY 5 5 7 C6 Adjust compass alignment ADJ Possible settings are 000 to 359 Default setting is 000 Compass transducer al...

Page 24: ...itions discovered as a result of the inspection could cause sudden loss of Autopilot control with consequential danger It is recommended that all items referenced in the following table be inspected before commencing any cruise Type Equipment Checks Remedy Inspection frequency Hydraulic Oil reservoir level Correct Fill 200 hrs Oil condition Discoloration Contamination Flush system and replace the ...

Page 25: ...D number 7 2 Symptom Cause Action In the table below causes marked are more likely to occur during installation or when rewiring has taken place Symptom Cause Action Autopilot turns off Voltage below mini mum Make sure 12 24 V is applied to battery terminals at Servo Unit Autopilot does not turn on Voltage not applied Make sure 12 24 V is applied to battery terminals at Servo Unit Voltage polarity...

Page 26: ...l motors loudspeakers etc Autopilot wanders on all headings Severe magnetic interfer ence Choose another compass location Air in hydraulics Fill and purge the steering system Slack in the steering system Repair any loose or worn parts Rudder transmitter potenti ometer is noisy or inter mittent Replace rudder potentiometer Compass damaged inter mittent wiring connection Repair any loose or worn par...

Page 27: ... P2 SEA NMEA does not engage NAV arrow does not come on NMEA receiver not installed correctly Check receiver settings for proper output No NMEA 0183 data re ceived Check Nav cable for connection to the correct port Unreliable NMEA data de tected upon engagement Check connections and setup in transmitting in strument No active waypoint Activate a waypoint After some use NAV arrow does not come on P...

Page 28: ...t format 11 Remote control setup error Command can not be executed Check connections and settings 12 No response from navigator Check navigator connection and set tings 13 Waypoint not defined Define a waypoint 14 Impossible command when used with an external NMEA navigator Use only possible command 15 Impossible command when in Autopilot mode Use only possible commands 16 Auto deviation is not po...

Page 29: ...ower 31 Autopilot compass input failure in Autopilot standalone connection Check compass connection at Autopilot Servo Unit 32 Autopilot compass input failure in Autopilot Nexus Network connection Check compass connection at Nexus Server or at the Compass Data in strument 33 Received wind data input failure Check wind wire connection 34 Autopilot calibration failure Check for air in the system and...

Page 30: ...ompass RAI 8 1 3 Servo Unit A 1510 Dimensions 160 x 110 x 38 mm 8 7 x 5 7 x 2 2 Weight 420 g 14 8 oz Enclosure Splash proof Cable 8m 26ft Nexus cable Power supply 12 or 24 V DC 10 30 V Power consumption 3 W plus drive unit demand Current consumption 0 3A at 12V Max motor output drive 15 A Output NMEA 0183 compass RAI 8 1 4 Rudder Angle Transmitter Dimensions 70 x 70 x 75 mm 2 7 x 2 7 x 3 0 Transmi...

Page 31: ... the Nexus application notes 8 3 Accessories 8 3 1 Autopilot instrument Additional Autopilot instruments Art No 20445 5 may be added They are connected in a daisy chain fashion from one to the other matching colours on terminals Control may be transferred from one instrument to another by simply pressing any pushbuttons except the OFF push button on the instrument where active control is desired A...

Page 32: ...r local Nexus dealer for more information Art No Nexus Completes 20445 1 Speed Log complete with transducer 20445 2 Depth complete with transducer 21440 Wind Data complete with transducer 21732 Compass Data complete with 35 tilt transducer 21033 1 GPS Navigator complete with GPS Antenna 20445 3 Multi Control instrument complete with Server Art No Nexus Transducers 20700 Log Temp 0 30 KTS 8 m 26 ft...

Page 33: ... for two Maxi repeaters 69995 Mast bracket XL for Multi XL and standard Nexus 110x110 21556 Connection box Nexus Network 21453 Connection box Wind Data and Compass incl 6 m 19 ft cable 21248 1 PC Interface FD Full Duplex NMEA with 1 m 3 3 ft cable and a 3 disc 20438 Instrument cover Nexus instruments 110 x 110 mm 20443 Nexus extension cable per meter 21266 8 Nexus cable 8 m 26 ft with wire protect...

Page 34: ...enne CHK CHecK CLR CLeaR COG Course Over Ground CTS Course To Steer d differential DEV DEViation DGPS Differential GPS dGPS differential GPS DTW Distance To Waypoint E East Edit Edit EEPROM Electroniically Erasable Programmable Read Only Memory EMC Electro Magnetic Compatibility EN European Norm GPS Global Positioning Network HDC HeaDing Compass HDM HeaDing Magnetic HDT HeaDing True HM Heading Mag...

Page 35: ...ile NMEA National Marine Electronic Association OCA Off Course Alarm PCA Pilot Course Alarm PWR PoWeR RAM Random Access Memory RET RETurn RRS RuddeR Speed RUD RUDder S South S A Selective Availability SAT SATellite SEA SEA SEC SEConds SOG Speed Over Ground STR STeeR tru true USR USeR VAR VARiation VER VERsion W West WP WayPoint XTE Cross Track error The boat is left of the desired track APPENDIX ...

Page 36: ...35 The boat is right of the desired track Apparent wind angle from port Apparent wind angle from starboard Rudder angle port Rudder angle starboard Minus _ Plus APPENDIX ...

Page 37: ...r by its national distributors or operation outside the environ mental parameters specified for the Product The Manufacturer will not compensate for consequential damage caused directly or indirectly by the mal function of its equipment The Manufacturer is not liable for any personal damage caused as a consequence of using its equipment The Manufacturer its national distributors or dealers are not...

Page 38: ...OR OWNER Name Street City Zip Code Country Product name Serial number A B C 1 2 3 4 5 6 7 Date of purchase _________________________Date installed ______________________________ Dealers stamp Tick here if you do not wish to receive news about future products WARRANTY ...

Page 39: ... the installation as neat and simple as your boat will allow Plan where to position the transducer and the instrument Think about leaving space for additional instruments to be fitted in the future A few do nots you should consider Do not cut the cables too short Allow extra cable length at the instrument so it can be disconnected for inspection without having to disconnect all attached cables Do ...

Page 40: ...urface Mount the instrument so that it can be reached by the helmsman to transfer from manual to automatic steering is satisfactory protected from outer damage is at least 500 mm away from radio receiving equipment has sufficient clearance from behind for the instrument housing and cables Note The instrument can be mounted right next to a magnetic com pass 9 3 2 Installing instrument Place the adh...

Page 41: ... to the other or in a star configuration matching colours as above The instrument cable should be connected to the Servo Unit terminals marked Bus Control head s matching the colours as indicated see drawing in connection Servo Unit below 9 4 Wire thickness Important Use the following table to determine wire thickness Total distance from battery to Servo Unit and distance from Servo Unit to pumpse...

Page 42: ... Connecting Servo Unit Servo Unit connections should be according to below drawing Note If any waterproof cable glands do not have cables inserted install the short rubber plug provided in order to maintain water tightness If many options are connected and not enough glands are available use a separate junction box and route the excess wires through one large cable in one of the large glands Note ...

Page 43: ...switch 9 5 5 Dip switches The main circuit board has 2 dip switches which must be pre set during installation to suit the installed configuration Important With power turned off to the system do the following a Locate dip switch for 12 or 24 32 VDC voltage and make sure it is set to the voltage supply connected b Locate dip switch for solenoid valve or pumpset and make sure it is set to the type o...

Page 44: ...ounted close to the rudder stock and driven by its ball joint linkage according to the drawing shown below The linkage should be linear such that 35 of rudder movement drives the arm 35 Small errors will not affect Autopilot operation but will cause inaccurate indication on the rudder angle indicator If possible the linkage on the rudder transmitter should be adjusted so that the digital rudder an...

Page 45: ...Figure 1 Typical installation on a boat with mechanical steering in cluding Pumpset PF 0 3S with solenoid Figure 2 Typical installation on a boat with hydraulic steering including Pumpset PF 0 3 9 9 INSTALLATION Solenoid Hydraulic Pipes Solenoid or block valve Hydraulic Pipes ...

Page 46: ...prevent hunting overshoot of the rudder To adjust anti hunt setting first complete procedures in described in sections Setup Dockside Testing and Sea Trials Activate the Autopilot and with the pumpset running make 10 course changes to port and starboard If the rudder hunts i e oscillates rapidly back and forth during these course changes gradually increase the anti hunt control i e adjust VR1 trim...

Page 47: ...ore the steering begins to move due to air in the system Continue to press and hold the push button until the steering reaches its stops Then reverse direction with the opposite push button Repeat this procedure 10 times or more until the system appears to move smoothly After 5 or 10 minutes of this purging let the system rest so that entrained air can settle out of the oil After 5 minutes of rest...

Page 48: ...y determine and correct how wires and pipes are connected It will also learn how the boat reacts on different rudder commands and automatically calibrate itself The APC routine automatically sets RUD SEA CRD ATC and RRS Select P7 APC To unlock press KEY To change to On press LEFT or RIGHT To activate the APC press KEY All 4 page arrows at top of display will now be lit to confirm the APC procedure...

Page 49: ...ng that can be used on the boat at the current cruising speed and load in calm waters 4 Continue making 40 course changes while slowly increasing the Counter Rudder CRD setting until the boat settles onto course with only one overshoot of 2 to 3 or less On some boats the RUD setting may have to be decreased by one position to get the boat to control properly The RUD and CRD settings are set to the...

Page 50: ... applies more rudder as necessary to reduce any persistant errors to zero Such errors may exist due to wind waves or other unbalanced forces such as single screw operation of a twin screw boat an off centre tow or weather helm on a sailing boat If the trim time is set too high it will take a long time to eliminate the course error If it is set too low it can start to degrade course stability In ge...

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