Postfach 1166 D -- 24100 Kiel Germany Tel +49--4 31--30 19--0 Fax +49--4 31--30 19--291 Email Service@raykiel.com www.raytheon--marine.com 3578E/102--886/885.DOC032 Edition: Apr 12, 2002 Revised: Dec. 04, 2002 Revised: DEC. 19, 2002 AUTOPILOT NP2035 Type 102--886 NG002 SERVICE MANUAL 1 Installation and First Setting into Operation 2 Care, Maintenance, Repair and Spare Parts Catalogue Actually no synchro input possible Weitergabe sowie Vervielfltigung dieser Unterlage, Verwertung und Mitteilung ihres Inhaltes nicht gestattet, soweit nicht ausdrcklich zugestanden. Zuwiderhandlungen verpflichten zu Schadenersatz. Copying of this document, and giving it to others and the use or communication of the contents thereof, are forbidden without express authority. Offenders are liable to the payment of damages. Toute communication ou reproduction de ce document, toute exploitation ou communication de son contenu sont interdites, sauf autorisation expresse. Tout manquement cette rgle est illicite et expose son auteur au versement de dommages et intrts. Sin nuestra expresa autorizacin, queda terminantemente prohibida la reproduccin total o parcial de este documento, as como su uso indebido y/o su exhibicin o comunicacin a terceros. De los infractores se exigir el correspondiente resarcimiento de daos y perjuicios. Service Manual AUTOPILOT NP2035 Autopilot 3578E/102--886/885.DOC032 Edition: Dec. 19, 2002 Service Manual AUTOPILOT NP2035 3566E/102--886.DOC032 Edition: Dec. 19, 2002 Autopilot Service Manual AUTOPILOT NP2035 3578E/102--886/885.DOC032 Edition: Dec. 19, 2002 SAFETY REGULATION " Warning! Caution during maintenance and repairs: Avoid contact with live electrical circuits! All relevant safety regulations such as, e.g. VDE, VGB4, OSHA 1919 and other relevant safety standards must be observed. " Caution! Maintenance and repairs must only be carried out by trained and qualified personal with knowledge of the national safety regulations for electrical devices. Observe handling regulations! Electrostatic sensitive components. Removal or insertion of a subgroup or printed wiring board with live voltage can lead to severe damage. Never insert fuses with other values than those stipulated! " Warning! In the configuration mode no alarm will be shown. The setting of the ships parameters in configuration mode should take place at the quay (dock side). " Attention! Actually no synchro input is possible! Service Manual AUTOPILOT NP2035 3578E/102--886/885.DOC032 Edition: Apr 10, 2002 Autopilot NP2035 Autopilot Service Manual I Edition: Dec. 19, 2002 3578E/102--886/885.DOC032 CONTENTS PAGE 1 Installation and First Setting into Operation 1--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Safety Notes 1--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Installation 1--2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 Mounting Instructions 1--2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Terminal Assignment 1--2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Planning the installation and instruction for installation 1--3 . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Operator unit 1--3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2 Connection unit 1--3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3 Rudder angle transmitter unit 1--3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Basic version: Installation and setting into operation 1--4 . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1 Installing the connection unit 1--4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2 Installing the operator unit (desk mounted) 1--5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2.1 Mounting the rudder angle transmission system 1--6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Establishing cable connections 1--9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 General 1--9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.2 General information about establishing a ground connection 1--10 . . . . . . . . . . . . . . . . . 1.5.3 Connection to connection unit 1--11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.3.1 Cabling of the operator unit and the control unit 1--13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4 Check of internal voltages of I/O--PCB 1--14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Setting Parameter to the ship 1--15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1 Electrical calibration of Offset of the Feedback--electronic Loop 1--16 . . . . . . . . . . . . . . 1.6.2 Electrical calibration of Rudder steering 1--17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2.1 Adjusting the offset of the Feedback--circuit 1--18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2.2 Adjustment of the rudderscale of the feedback--circuit (Limit/Values) 1--18 . . . . . . . . . . 1.6.2.3 Adjustment of Rud Slack (Limits/Values), Single Pump operation 1--19 . . . . . . . . . . . . . 1.6.2.4 D--Return Adjustment 1--19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2.5 Adjustment of double--pump operation 1--20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2.6 Offset Adjustment of the analog Nominal--rudder lines 1--20 . . . . . . . . . . . . . . . . . . . . . . 1.6.2.7 Adjustment of the Rudder 1 Feedback Input 1--21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3 Adaption at the Connection unit 1--23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.1 Jumper at the I/O--PCB and their meaning 1--23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.2 Jumper at the backplane and their meaning 1--24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4 Checking/Changing the Configuration of the Autopilot 1--25 . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.1 Checking/Changing the Configuration of the Operator Unit 1--25 . . . . . . . . . . . . . . . . . . 1.6.4.2 Checking the Configuration of the System 1--27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.3 Changing the Configuration of the System 1--28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.4 Configuration Survey 1--32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.5 Configuration DC Solenoid valve (24V Operation only) 1--44 . . . . . . . . . . . . . . . . . . . . . . Autopilot NP2035 Service Manual II Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.5.1 DC Solenoid Valve Control with Common Negative Connection COMMON 1--44 . . . 1.6.5.2 DC Solenoid Valve Control with Common Positive Connection COMMON 1--44 . . . . 1.6.5.3 AC Solenoid Valve Control with additional relais 1--45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.6 Calibration of the magnetic Sonde 1--46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Care, Maintenance, Repair and Spare-parts Catalogue 2-- 1 . . . . . . . . . . . . . . . . . . . 2.1 Safety Instructions 2-- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Care and Maintenance 2-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Care 2-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Maintenance 2-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Repairs 2-- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Removing the Cover of the Control Unit 2-- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Replacing a PCB 2-- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Fuse Replacement 2-- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Significance of LED signals 2--8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 CPU PCB 102--885.101 2--8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2 I/O PCB 102--880.100 2--8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3 I/O--Manager 102--885.100 2--9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4 Configuration of the CPU PCB 2--10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Spare Parts Catalogue 2--11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 Notes on Ordering 2--11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Technical Data 2--12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Electrical Data 2--12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Constructional features of the NP2035 Autopilot system 3-- 1 . . . . . . . . . . . . . . . . . . . . . 3.1 Basic System 3-- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 Operator Unit 3-- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.1 Function of Operation Unit 3-- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Control Unit 3-- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Monitoring Functions of the NP2035 3-- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Monitoring the Heading Controller 3-- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Monitoring the Serial Data Transfer 3-- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 Plausibility Monitoring of the Connected Periphery Devices 3-- 9 . . . . . . . . . . . . . . . . . . 3.2.4 Monitoring the Control Unit 3--10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 NMEA 0183 Format 3--12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autopilot NP2035 Autopilot Service Manual III Edition: Dec. 19, 2002 3578E/102--886/885.DOC032 Annex: Spare Parts Catalogue Annex 1--1 Summary of Configuration Annex 1--2 Short Instruction Annex 1--3 Stand--Alone System Annex 1--4 Connection on terminal board L1 Annex 1--5 Connection on terminal board L2 Drawings: Feedback Unit, Dimensional Drawing 101 D 528.HP005 . . . . . . . . . . . . . . . Connection Unit,Dimensional Drawing 102 D 885.HP005 . . . . . . . . . . . . . . Operating Unitm NP2000, Assembly Drawing 102 D 886.HP005 . . . . . . . . Front panel, compl., Assembly Drawing 102 C 886.HP007 . . . . . . . . . . . . . I/O PCB Autopilot, Configuration Sheet 102 D 880.HP100 . . . . . . . . . . . . . Backplane NP60, Configuration Sheet 102 D 880.HP010 . . . . . . . . . . . . . . CPU--PCB, Configuration Sheet 102 D 885.HP101 . . . . . . . . . . . . . . . . . . . Cable NB60 D 057 HP010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable NB60 D 053 HP010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autopilot NP2035 Service Manual IV Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Autopilot NP2035 Autopilot Service Manual 1--1 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1 Installation and First Setting into Operation 1.1 Safety Notes ATTENTION In opened devices or desks, voltages representing a risk of electric shock are applied. -- SAFETY INSTRUCTION -- As a matter of principle, the system is to be made dead when installation work is performed on the equipment as well as during disassembly/assembly of components or dur- ing alteration of the circuitry. ATTENTION The adjustment work described in this section must only be carried out by trained service personnel observing all safety measures! For all work that results in a movement of the rudder, a pre- vious check must be made to guarantee that neither person- nel nor material will be in danger from the rudder or the steering gear! Autopilot NP2035 Service Manual 1--2 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.2 Installation 1.2.1 Mounting Instructions Installation of the equipment is specific to the actual ship and is to be carried out in ac- cordance with the accompanying dimensional drawings. The following conditions must be observed at the place of installation (see section 2.6 Technical Data): -- permissible type of enclosure -- permissible ambient temperature -- permissible humidity 1.2.2 Terminal Assignment The terminal assignment of the control depends on the mounted electronics PCBs. On principle two different versions are distinguished: - with internal FU amplifier PCB, switching or analog (see Fig. 1--2) - with external FU amplifier (analog or switching) Autopilot NP2035 Autopilot Service Manual 1--3 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.3 Planning the installation and instruction for installation 1.3.1 Operator unit (dimensional drawing 102 D 886.HP007) Conditions at installation site: The device must be located in a position where it can be easily seen, and from which it is comfortable to operate. The data required for flush mounting the equipment are provided in dimensional drawing 102 D 886.HP007 and are binding (cut--out section and drilling scheme). NOTE Before starting work check that there is sufficient room beneath the cut--out section you have selected to carry out the necessary sawing work! 1.3.2 Connection unit (dimensional drawing 102 D 885.HP005) Condition at place of installation: The connection unit should be sited within a radius of appr. 3m from the operator unit. It is essential to ensure that the amount of clearance specified in the dimensional drawing above the connection unit is available. 1.3.3 Rudder angle transmitter unit (dimensional drawing 101 C 528.HP00 Condition at place of installation: 1. if linkage transmission has been selected, it is essential to ensure that it cannot be blocked by any loose objects! All cables within this radius must be fastened down. 2. if toothed--belt transmission has been selected, it must be correctly pre--tensioned beforehand. All nearby cables must be fastened down. Autopilot NP2035 Service Manual 1--4 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.4 Basic version: Installation and setting into operation 1.4.1 Installing the connection unit NOTE: Please see drawing 102 D 885.HP005 for detailed dimenion data. The connection Unit should preferably be bulkhead--mounted. The distances between mounting screws can be taken either from the dimensional drawing or from the connec- tion unit itself. The connection unit is mounted by fitting 4 screws through the recesses provided. 5 mm wood screws should be used to fasten the unit onto wood, the length of screw should be chosen to suit the thickness of the base. M5 screws should be used to fasten the unit onto metal, the length of screw will depend on the thread length in the base. Fig. 1--1 Mountig the connection unit Autopilot NP2035 Autopilot Service Manual 1--5 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 NOTE: When mounting the connection unit ensure there is sufficient claer space around the connection unit. It must be possible to replace the covers and screw them on without hindrance . Ensure there is sufficient space for the on--board wiring! 1.4.2 Installing the operator unit (desk mounted) NOTE: Please see dimensional drawing 102 E 886.HP005 for detailled dimensional data. Prior to fitting, a cut--out section should be cut away from the desk as indicated in the dimensional drawing. Autopilot NP2035 Service Manual 1--6 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.4.2.1 Mounting the rudder angle transmission system NOTE: Please see dimensional drawing 101 C 528.HP005 for detailed dimension data. Depending on the amount of space available on board and the working range of the rud- der, one of two types of transmission can be selected. (1) Linkage transmission With this type of transmission the appropriately adjusted flat steel piece supplied with the unit must be mounted to the rudder spindle (if not already present) in ac- cordance with the dimensional drawing. The transmission ratio is 1 : 1 and can be configured for operating angles of 0 to 45. The drive shaft consists of a driving lever, two ball and socket joints and a connection threaded round bar. Once the driving rod has been carefully adjusted, the threaded round bar between the two ball and socket joints should be shortened to the required length. Systems withup to a maximum of two feedback units will therefore require two driving rods. After fitting, transmission should not be endangered from loose objects in the area of the lever. All acbles situated in the action range of the lever must be fastened down. Autopilot NP2035 Autopilot Service Manual 1--7 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 (2) Chain drive (Refer to dimensional drawing 101--528.HP005) For rudder angles of max. +90 , the drive of the feedback unit should be via chain wheels and chain. The transmission ratio from chain drive is 2 : 1. The tapholes (e.g. M6, depth 20mm) required for fastening the chain wheel to the rudder stock are to be centered on the plane surface of the rudder stock. Then the chain wheel is to be screwed on and to be pinned by means of cylindrical pins. To ensure automatic chain tension, a chain tightener is to be mounted and to be pla- ced in accordance with space conditions (chain tightener included in the scope of delivery). NOTE: For systems of 2 feedback units, two chain wheels -- arranged in parallel -- are to be centered and screwed on the plane surface of the rudder stock, and pinned. Autopilot NP2035 Service Manual 1--8 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3 1 4 2 5 6 Fig. 1--2: Control Unit 1 I/O--PCB 102--880--100 2 CPU PCB 16MH 102--885.101 3 I/O Manager II 102--885.100 4 Backplane 102--880.10 5 Terminal board L1 6 Terminal board L2 For connections at the terminal boards L1 and L2 see annex 1--1 and 1--2. Autopilot NP2035 Autopilot Service Manual 1--9 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.5 Establishing cable connections 1.5.1 General Information Caution When establishing cable connections ensure that the cables are disconnected from the power supply. It is essential to ensure that all cables are disconnected from the power supply, if necessary measure the voltage beforehand and/or disconnect the relevant distributor. In order to ensure that the system operates correctly, it is essential that you follow the procedures described below for establishing cable entries. Autopilot NP2035 Service Manual 1--10 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.5.2 General information about establishing a ground connection In order to comply with the stringent EMC requirements, please abide by the information given below regarding cable connections. Use the cable types specified. Ground connections should be connected to the operator unit case, to the junction box and to the feedback unit. It is essential to ensure that these connections have a common reference (ships ground)! Note: Any additional components (options) must also be connected to the common reference! or Fig. 1--3: Establishing a ground connection All ground connections must be made as shown in Fig. 1--3. The grounding cable attached to the cable bracket must possess a cross-section of mini- mum 1.5 mm 2 . The cable bracket should be mounted between two toothed discs. Ground connections must be free of corrosion and well fastened. Autopilot NP2035 Autopilot Service Manual 1--11 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.5.3 Connection to connection unit -- Strip approx. 120 mm of the cable. Make sure you do not damage the shielding layer. -- Carefully peel back the shielding layer and strip the cable to approximately 6 -- 7 mm (see Fig. 1 appr. 120 mm Shielding appr. 6--7 mm Fig. 1--4: How to strip the connection cable -- Loosen or screw out the top clip from the cable entry concerned on the junction box . -- Place the cable into the bottom part of the clip so that the peeled back shielding can be well enclosed by the cable clip. -- Fix the cable with the shielding by tightening the two clamp screws. Autopilot NP2035 Service Manual 1--12 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Shielding Terminal block Ground connection Fig. 1---5: Making cable connections Autopilot NP2035 Autopilot Service Manual 1--13 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.5.3.1 Cabling of the operator unit and the control unit The cabling between the operator unit and the controll unit has to be performed accor- ding section 1.5.3. It is essential to ensure that all cables are disconnected from any power supply or dataoutput before cabeling. For establishing an earth connection it is essential, that devices are connected to a common earth (see also drawings NB60 D 057 HP010 and NB 60 D 053 HP010). 2 3 4 5 6 1 TX+ 2 TX-- 3 RX+ 4 RX-- 5 GND 6 Case 1 14 +24VDC 17 0V 20 Case B5 B6 B3 B2 Supply Operating Unit 20 17 14 15 24VDC1 (8--32 VDC Shipsmains) 18 0V 21 Case Supply Autopilot Equipment 20 17 14 NB60 057 NB60 053 Fig. 1---6: Connections between operator unit and control unit Autopilot NP2035 Service Manual 1--14 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.5.4 Check of internal voltages of I/O--PCB The internal voltages +5 VDC, --15 VDC and +15 VDC can be measured against TP 0 (signal ground). The +24 VDC is to be measured against terminal strip L2 / 17, 18, 19 (0 V) ! +5VD C +3% I 17 18 19 0V L2 V V V V +24 VDC (Variation depends on ships mains --15VDC +5% +15VD C +5% Fig. 1--7: Measuring points for internal voltage at the I/O--PCB Autopilot NP2035 Autopilot Service Manual 1--15 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6 Setting Parameter specific to the ship The Autopilot NP2035 is supplied with certain ship-specific pre-configured nauti- cal parameter values that are necessary for the system to operate.These parameters can be adapted or changed to suit the layout of the specific system. Note:In principle it is necessary to configure ship-specific parameters only when putting the system into operation for the first time, or when extending the system (for example, after an option has been added). Autopilot NP2035 Service Manual 1--16 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.1 Electrical calibration of Offset of the Feedback--Electronic Loop Preconditions: -- Use the manual steering control to set the rudder to midships (0). -- Connect the measuring instrument on TP 7 -- I and TP 6 -- +. Calibration Turn potentiometer R149 (on the I/O card) until the voltmeter indicates 0 V. TP 7 Signal GND TP 6 R149 Rudder Offset CPU--PCB R154 Rudder Scale Fig. 1--8: Offset calibration Autopilot NP2035 Autopilot Service Manual 1--17 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.2 Electrical calibration of Rudder steering Follow Up Calibration Config Follow Up Mode Steering mode selector to AUTO. By a wire link at terminal board L1.10 to L1.12 the service--mode is selected and the ca- libration of he amplifier of the rudderengine is possible. It is possible to select/deselect the service--mode by operating the buttons Alarm and Set for appr. 4 sec. (see section 1.6.4.1) -- FU Set Up Y....N is indicated. The message Config Follow Up is displayed at the display of the operation unit. Calibration values are called--up via the the key Limits/Values at the operating unit. Settings at the operation unit: The calibration values can be incremented by the key upwards and decrementd bydownwards. On operating the key Set are stored in the EEPROM. Calibration modes in service mode Config Follow Up: Man Rudder -- To set rudder in steps of 10 PORT/STB Rud.Slack 1 -- Adjustment of rudder slack in single--pump--mode Rud.Slack 2 -- Adjustment of rudder slack in double--pump--mode D--Return 1 -- Compensation of rudder--deviation D--Return (single--pump--mode) D--Return 2 -- Compensation of rudder--deviation D--Return (double--pump--mode) Offs. Ana 1 -- Offset--compensation of the set--rudder--line 1 Offs.Ana 2 -- Offset--compensation of the set--rudder--line 2 Autopilot NP2035 Service Manual 1--18 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Below mentioned sequence has to be followed 1. Adjusting of the rudder--feedback Circuit (Offset and Scale) by potentiometers. If the rudder does not follow the ruddercommand, change the polarity of the feedback supply voltage from L1.32 to L1.35. If the rudder moves to the opposite side, change the starboard/port cable connections (see connection diagram, section 1.6.5.1) 2. Adjusting of the rudder slack and the rudder--overshoot D--Return (if necesary). 3. After adjustment the cable link between L1.10 and L1.12 has to be removed or FU Set up must be deselected. Respective potentiometers on the I/O--PCB 102--885--100 -- Adjusting or the Offset of the Rudder Feedback Elektronic with potentiometer R149 -- Rudderscale of the Rudder Feedback Elektronic with potentiometer R154 1.6.2.1 Adjusting the offset of the Feedback--circuit Activate the Offset adustment of the feeback--circiut loop (Limits/Values--key) Set the rudder to 0 (with Set rudder value = 0). Adjust with the offset potentiometer R 149 (I/O--PCB) the rudder to 0. 1.6.2.2 Adjustment of the rudderscale of the feedback--circuit (Limits/Values) Set nominal rudder to 10 / --10 (display indication: Port = --10; Stb = +10 ) (with SetRudder Value = 10(--10). Adjust with the rudderscale potentiometer R154 (I/O--PCB) the rudder to 10. Optimize this adjustment at 30 . Autopilot NP2035 Autopilot Service Manual 1--19 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.2.3 Adjustment of Rud Slack (Limits/Values). Single Pump operation Activate key: Limits/Value . Rud Slack (Default--Setting=1) decrease until the rudder starts to hunt. Increase this set value until the rudder is to stabilised. Set nominal value to 10 (--10 ) and let the rudder run to 0 . Continue to optimize Rud Slack if necessary. After optimized adjustment of Rud Slack below mentioned adjustment have to be repeated: -- Offset value with potentiometer R149 -- RuderScale with potentiometer R154 If the rudder runs over the nominal value, there is the possibility to switch off the rudder by D--Return 1 (see section 1.6.2.4) before it reaches the nominal value. 1.6.2.4 D--Return Adjustment Activate key Limits/Values. With this parameter (D--Return) it is possible to create a rudder--lead. This rudder--lead switches off the rudder--control before the nominal value is achieved. The D--Return--value has to be set in such a manner, that an overshoot of the rudder over the nominal value is prevented. Possible settings are 0 to 16. Setting 0 means that the D--Return is switched off, 10 is the maximum setting. Has to be checked!!! In case of troubles on the feedback--signal (50Hz) the D--Return value has to be redu- ced or set to 0 otherwise there will be a multilple valve--activation. The safety of the valve--control has highest priority. The respective switching--pulses are monitored as LED--control--signals at the I/O--PCB. Autopilot NP2035 Service Manual 1--20 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.2.5 Adjustment of double--pump operation (Switch on pump 2) Because the rudder--moving--speed is duplicated with 2 pumps, the rudder slack should be adapted to fast rudder operation. Rud Slack 2 (Default = 1 ) This adjustment procedure has to be performed according to section 1.6.2.3. Scale and offset setting should not be changed. D--Return 2 (Default = 0) Because of the higher rudder--moving--speed there may be a requirement to set another D--Return. This procedure has to be performed according to section 1.6.2.4. 1.6.2.6 Offset Adjustment of the analog Nominal--rudder lines Activate key Limits/Value. Select parameter Offs. Ana 1. Measure the volatge at the analog output L1.1 L1.2 while the rudder position is 0. The offset value can be compensated stepwise (depending on polarity + or --) within a set range of 0...+/-- 200. Select parameter Offs. Ana 2 Measure the volatge at the analog output L1.4 L1.5 while the rudder position is 0. The offset value can be compensated stepwise (depending on polarity + or --) within a set range of 0...+/-- 200. Autopilot NP2035 Autopilot Service Manual 1--21 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.2.7 Adjustment of the Rudder 1 Feedback Input If the feedback input receives its signal from a external Follow--Up amplifier or from a Rudder--position amplifier, than an offset and scale adjustment has to be performed also. The 10V has to be optimized to max. rudder position. To do this, it is possible to display the actual rudder value at the operating unit (use the display key to look for the actual rudder). Set rudder to 0 position and adjust the offset to 0 with potentiometer R 149. Set rudder to Stb 30 and adjust 30 with potentiometer R 154. Check this adjustment at rudder position of Port 30. (1) Rudder does not reach its end position If the rudder--end--position is not reached by the setting of the nominal value, the amplification factor has to be increased by potentiometer R154 (see LEERER MERKER) until the actual value at the display of the operating unit is identical to the mechanically position of the rudder. (2) Rudder--end--position is reached untimely The amplification factor has to be decremented with potentiometer R154 until the nominal value is identical to the mechanicaly position of the rudder. (3) Offset correction After the adjustment of the nominal values we recommend a correction of the elec- trically offset. See section 1.6.1 . Rudder 2 Feedback input: This input is fixed to +/-- 10V according max. rudder and cannot be adjusted. After the adjustmens of the autopilot control, the jumper between L1.10 and L1.12 has to be removed. FU set up has to be switched off via operator unit. Autopilot NP2035 Service Manual 1--22 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 TP 7 Signal GND TP 6 R154 Adjustment of Rudder scale CPU--PCB R149 Adjustment of Rudder offset Fig. 1--9: Electrically Adjustments of rudder position (rudder scale) Autopilot NP2035 Autopilot Service Manual 1--23 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.3 Adaption at the Connection unit Depending on the additionally equipment, the jumpers at the backplane and at the I/O-- PCB have to be checked and be changed if necessary. 1.6.3.1 Jumper at the I/O--PCB and their meaning (see I/O--PCB AUTOPILOT CONFIGURATION SHEET 102D880 HP100) Jumperfield Funcion/ Reaction Jumper 2 1 2 1 4 4 3 3 B31 B32 Feddback unit 101--528 B31 3/4 and B32 3/4 2 1 B12 Synchro Input (from Gyro) B12 1/2 B12 Step Input (from Gyro) No Jumper at B12 Autopilot NP2035 Service Manual 1--24 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.3.2 Jumper at the backplane and their meaning (see BACKPLANE CONFIGURATION SHEET 102D880 HP010) Jumperfield Function/ Reaction Jumper COMMON + (Sperry Step) 1 2 3 4 S1 S2 S3 +24V 0V Step-- generation B12 1/2 to 15/16 COMMON - 1 2 4 (Sperry Step) 1 3 S1 S2 S3 +24V 0V Step-- gene-- ration B12 2/4 to 14/16 STEP 1 2 3 4 Step configuration for 1/6 Step Compass-- systems B32 1/2 3/4 5/6 SYNCHRO 1 2 3 4 Synchro configuration (1!1 rev.) Set jumper B32 at the I/O--PCB 102--880.100 B32 7/8 9/10 11/12 I/O BUS OPERATION 1 2 3 4 I/O--BUS Operation B24 1/2 3/4 CAN BUS OPERATION 1 2 3 4 CAN BUS Operation (configuration not possible) B24 5/6 7/8 Autopilot NP2035 Autopilot Service Manual 1--25 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.4 Checking/Changing the Configuration of the Autopilot ATTENTION No alarm is displayed during checking/changing the configu- ration of the autopilot. Therefore ships parameters should only be set or changed at the quay (dock side) only! 1.6.4.1 Checking/Changing the Configuration of the Operator Unit General: Indications Comment/Note Quit configuration menu Track Control During the configuration you can quit the configuration menu by pressing a func- tion or command key, e.g. TRACK CON- TROL. A RESTART is performed auto- matically. A prior configuration change will not be accepted! Changing a function or a value A d a p t i v M o d e Y N By actuating one of the DIM keys a func- tion or numerical value can be changed. The current function or value is flashing. Autopilot NP2035 Service Manual 1--26 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Indications Comment/Note 1 Calling up Follow Up Calibration Set simulta- neously for at least 4s FU Set up: Y N Y = Adjustment of Follow--Up Amplifier (Autopilot) Service Mode is deactivated. N = No adjustment of Follow--Up amplifier (Autopilot) 2 Calling up configuration menu Set A d a p t i v M o d e Y N Y = steering quality ECONOMY/PRECISION N = steering quality BASIC 3 Acknowledging the selection Set M o d e : P a n e l P a r a Panel = Change/show configuration of the operator unit Para = Change/show configuration of the system 4 Acknowledging the selection Set I n t e r f . T e s t : O K Test of interface between operator unit and control unit. In case of error Err. ap- pears in the text line 5 Acknowledging the test Set S o f t w a r e -- V e r s i o n 102 -- 885 P02 E00.xx Shows the current software version of the CPU PCB 68302 e.g.: E00.00 6 Acknowledging Set B a r -- L i m i t : 1 0 . 0 Resolution of the indication of the head- ing deviation. Possible values: 2.5, 5.0, 10.0, 20.0 X 7 Acknowledging Set P T y p e : H P N Operator unit priority: H =main unit P =parallel unit N =secondary unit 8 Acknowledging the selection Set B u z z e r : N Y Deactivate or activate acoustic signalling Autopilot NP2035 Autopilot Service Manual 1--27 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 Indications Comment/Note 9 Acknowledging the selection Set N e x t : R e s t a r t Changes are valid after a restart only. 10 Acknowledging the restart Set 1.6.4.2 Checking the Configuration of the System In order to allow later repairs (e.g. defective CPU PCB) to be quickly carried out, we rec- ommend that you enter into the configuration survey, in writing, the parameter settings. Indications Comment/Note 1 Calling up Follow Up Calibration Set simulta- neously for at least 4s FU Set up: Y N Y = Adjustment of Follow--Up Amplifier (Autopilot) Service Mode is deactivated. N = No adjustment of Follow--Up amplifier (Autopilot) 2 Calling up configuration menu Set A d a p t i v M o d e Y N Y = steering quality ECONOMY/PRECISION N = steering quality BASIC 3 Acknowledging the selection Set M o d e : P a n e l P a r a Panel = Change/show configuration of the operator unit Para = Change/show configuration of the system 4 Changing to Para M o d e : P a n e l P a r a Autopilot NP2035 Service Manual 1--28 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Indications Comment/Note 5 Acknowledging the selection Set P a r a m e t e r m o d e P a r a S h o w / C h a n g e 6 Acknowledging Set B a s i c P a r Y The first parameter of the configuration menu appears. Behind the parameter the actual value is indicated. 7 Acknowledging Set U s e r S t d I O D e f The next parameter of the configuration menu appears. 8 Acknowledging Set ..... With every pressing of the Set key, the next parameter appears. For a list of all parameters, see Section 1.6.4.4, page 1--32 9 Quit configuration menu Track Control During checking the configuration you can quit the configuration menu by pressing a function or command key, e.g. TRACK CONTROL. A RESTART is per- formed automatically. 1.6.4.3 Changing the Configuration of the System In order to allow later repairs (e.g. defective CPU PCB) to be quickly carried out, we rec- ommend that you enter into the configuration survey, in writing, the parameter settings made. General: Indications Comment/Note Quit configuration menu Track Control During the configuration you can quit the configuration menu by pressing a func- tion or command key, e.g. TRACK CON- TROL. A RESTART is performed auto- matically. A prior configuration change will not be accepted! Autopilot NP2035 Autopilot Service Manual 1--29 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 Indications Comment/Note 1 Calling up Follow Up Calibration Set simulta- neously for at least 4s FU Set up: Y N Y = Adjustment of Follow--Up Amplifier (Autopilot) Service Mode is deactivated. N = No adjustment of Follow--Up amplifier (Autopilot) 2 Calling up configuration menu Set A d a p t i v M o d e Y N Y = steering quality ECONOMY/PRECISION N = steering quality BASIC 3 Acknowledging the selection Set M o d e : P a n e l P a r a Panel = Change/show configuration of the operator unit Para = Change/show configuration of the system 4 Changing to Para M o d e : P a n e l P a r a 5 Acknowledging the selection Set P a r a m e t e r m o d e P a r a S h o w / C h a n g e Autopilot NP2035 Service Manual 1--30 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Indications Comment/Note 6 Changing to Change P a r a m e t e r m o d e P a r a S h o w / C h a n g e 7 Acknowledging Set D V B u s A d d r 1 2 > N The first parameter of the configuration menu appears. Here parameter No. 3 is displayed. The actual value is flashing. Now this value can be - acknowledged or - changed Acknowledging the value: Indications Comment/Note Acknowledging Set D V S o u r c e N r 1 2 > N The next parameter appears. Autopilot NP2035 Autopilot Service Manual 1--31 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 Changing the value: Indications Comment/Note Selecting the value D V B u s A d d r 1 2 > N Select the desired value, e.g. 1 or 2. Displaying more values D V B u s A d d r 1 2 > N If the desired value is not in the display, select > . Acknowledging Set D V B u s A d d r 3 4 > N The next value(s) appear(s) appear in the display, e.g. 3 und 4. Selecting the value D V B u s A d d r 3 4 > N Select the desired value, e.g. 3 or 4. Acknowledging Set D V S o u r c e N r 1 2 > N The parameter value is changed, the next parameter appears. For a list of all parameters, see Section 1.6.4.4, page 1--32 Note: Indications Comment/Note Going to the next parameter without changing the initial parameter value D V B u s A d d r 3 4 > N If you have selected a value (e.g. 4) other than the initial value (e.g. 1) and want to go to the next parameter with the initial value unchanged, select N. Acknowledging Set D V S o u r c e N r 1 2 > N The parameter value is not changed, the next parameter appears. For a list of all parameters, see Section 1.6.4.4, page 1--32 Autopilot NP2035 Service Manual 1--32 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.4.4 Configuration Survey In the following list you can see all parameters of the configuration menu, the possible settings and the default values. In order to allow later repairs (e.g. defective CPU PCB) to be quickly carried out, we rec- ommend that you enter into the configuration survey, in writing, the parameter settings made. The parameters can be divided into 3 groups: - basic parameters (No. 0 to 38) - track interface data (No. 39 to 44) - track control parameters (No. 45 to 88) If in a parameter group no parameter change is to be performed (e.g. Basic Par = NO), the configuration menu jumps to the next group (e.g. track interface data (No. 39)). (4) Service Mode Parameters The autopilot NP 2035 is designed to reach high performance track control acc. to DNV W1 classification. For that reason, it is equippedwithdifferent controllers for headingcontrol and track control function. This leads into additional parameters to be adjusted. The followinglist of track control parameters (started with itemNo. 45) includes some parameters which have to be adjusted in any case, fewparameters which have to be adjusted sometimes , parame- ters which have to be adjusted only acc. to the agreement of the development department and some parameters which are only for development department use (activation of special functions, to avoid new software versions for special behaving ships). The last two groups are labeled in the list. The parameter list for track control is frozen and can not be influenced by theuser. Thepara- meter settings done by the user influences only normal heading control function. Autopilot NP2035 Autopilot Service Manual 1--33 Edition: 1 3578E/102--886/885.DOC032 (5) Adjustment of Controller To reach high performance track control, the autopilot NP 2035 controllers for heading control and track control need different sets of parameters, which have to be adjusted separately. The track controller parameters are to be determined and adjusted complete separately. For that reason a special adjustment function is implemented. This function allows to adjust some of the track control parameters without entering track control mode. The procedure is the same as to adjust a standard heading controller. The parameters are named equal. The following procedure describes the steps for the adjustment: 1. Activate the Heading Controller Part of the track controller. Enter the ATCPAR menu and set ACTCrseCtl to ON (menu item No. 46). Having done this, the controller for normal heading control is switched off. After finishing the adjustment work at track controller, the normal heading controller has to be switched on again (setting ACTCrseCtl to OFF)! 2. Now adjust the ShipL, CR_act, R_act and Yaw_act parameters using heading control mode. 3. Switch off ACTCrseCtl!! 4. Adjust PivotPt using track control mode. No. Parameter Significance Possible Setting (Default value is underlined) Adjus- ted 0 BasicPar Setting basic parameters (activates menu item No. 1 to 39) ? YES, NO 1 UserStdIO Interface No. of test interface Def, 4, 5, 6 2 DVBus Is the NP2035 participant on the DV bus ? YES, NO 3 DVBusAddr DV bus address of the NP2035 0, 1, 2, ... 15 4 DVSourceNr General source No. of all NP2035 telegrams 0, 1, 2 ... 15 5 DVHeading Output of the heading signals from the NP2035 to the DV bus ? YES, NO Autopilot NP2035 Service Manual 1--34 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 6 DVHeadingNr Source No. of the heading telegrams 0, 1, 2, 3, ... 15 7 DVSpeed Is the NP2035 participant on the speed management of the DV bus (system speed) YES, NO 8 DVSpeedNr Source No. of the speed telegrams 0, 1, 2, ... 15 9 DVSpeed Send Suppresses the speed output of the autopilot to the DV bus. YES, NO 10 DVRudder Output of the actual rudder angle from the NP2035 to the DV bus ? YES, NO 11 Rate Gyro Rate gyro connected ? YES, NO 12 Variants Determines the interface of heading data input: C.Bus serial data (course bus) from STANDARD 20 equipment C.PCB step and/or synchro data via the heading/speed PCB C.Bus C.PCB 13 Magnet Magnetic compass connected to NP2035 ? YES, NO 14 MKSource (Magnetic com- pass source) Determines the interface of magnetic heading data input: C.Bus serial data (course bus) via STANDARD 20 equipment C.PCB synchro data via the heading/speed PCB C.Bus C.PCB 15 RoT--Tiller Rate--of--Turn tiller connected to NP2035 ? YES, NO 16 Spd: Determines the interface of the speed data input: -- Serial data via the course bus -- Direct feed in (Pulses) -- Feed in via the heading/speed PCB C.Bus Spd, IO--Pulse ser. VHW ser. VTG ser. VBW 17 Manoever Direct set course input with automatic R.o.T. adjustment? Yes With an adjusted R.o.T. of up to 120/min, the ship turns automatically with 120/min, when pressing and turning the rotary knob. With an adjusted R.o.T. of >120/min, the adjusted R.o.T. remains valid. No The course change is carried out with the adjusted R.o.T YES, NO Autopilot NP2035 Autopilot Service Manual 1--35 Edition: 1 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 18 ShipL (Ships length) Ships length in meters 20, 30, 50, 75, 100, 150, 200, 300, 400 19 MaxRudder (Maximum rud- der) Maximum rudder angle in .... 35, 45, 60, 90 20 RoTTi (Rate--of--Turn til- ler) Maximum rate--of--turn adjustable by the Rate--of--turn tiller in ... /min. 35, 45, 60, 90 21 RdTyp (Rudder Type) Type of Rudder DoubleR, BeckerR, SingleR 22 VarStd (Standard values for rudder varian- ce regulation) Use variance standard values: YES The rudder variance regulation is executed with standard values NO The dynamics of the rudder variance regulation can be specified (see No. 23 to 26) YES, NO 23 RegelB (Regulation range) Define regulation range for Yawing +2 ... -2, +2 ... -1, +2 ... 0, +1 ... -2, +1 ... -1, +1 ... 0, 0 ... -1, 0 ... 0 24 Erhoe (Increase) When changing-over from PRECI- SION to ECONOMY, the Yawing value is automatically increased by 1 or 2. This results in in a slower regula- tion behavior +1, +2 25 VariFak (Variance factor) Factor which modifies the rudder vari- ance value (see No. 23) 8, 4, 2, 1, 1/2, 1/4, 1/8, 1/16 26 IntSchw (Integrator thresh- old) Integrator input threshold 1, 1.5 27 IntITLim If the time during track control ex- ceeds this value (in hours) and the system is switched to course control the rudder variance regulation is ini- tialized first 0, 1, 2, 4, 6, 9, 12, 24, 36, 48, 9999 28 StFInterv (for future use) must always be 0 0, 1, 2, ... 10 29 RudderTrim Rudder Trim ON/OFF? Enables/disables rudder trim option at operator unit ON/OFF Autopilot NP2035 Service Manual 1--36 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 30 Rudlimwarn (Rudder limit warning) Rudlimwarn act / set? act The alarm sounds if the actual rudder went into the rudder limitation set The alarm sounds if the preset rudder went into the rudder limitation set/act 31 Rud.Offs (Rudder Offset) Rudder offset adjustment (in degrees) for correction of ahead run --3.0, --2.5, --2.0, --1.5, --1.0, --0.5, 0.0, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0 32 RemoteTil Clears items 33 and 34. Effective only in connectionwith Remote Tillers. YES, NO 33 RdSpeed If a value <> 0 is entered on operation with Remote Tillers, the rudder speed is monitored to ensure that the set va- lue is kept. In the event of a conside- rable deviation an alarm is released. 0, 1, 2, ... 10 34 RdRduce[%] The read--in rudder actual value can be reduced by the set value. Applies only to Remote Tiller Operation. 0, 1, 2, ... 10 35 Alarm level The status outlets on NB03--888 can be set to a different meaning. 1 2 36 Grad.control Enables/disables heading jump (gra- dient) monitor and heading jump com- pensation of selected heading sensor. YES, NO 37 GradientVal This parameter defines the threshold of the heading jump below no com- pensation is out, above a compensa- tion takes place. In case of a com- pensation the jump amount is taken to correct the preset heading in the same direction. An alarm (heading jumped) is generated. 8, 10, 12, 14, 16, 18, 20 /s 38 HDGJmpAI Enables / disables the heading jumped alarm at operator unit. The alarm is generated when a certain bit is set by gyro compass STANDARD 20 on course bus. OFF / ON 39 TRACKDAT Setting track interface data (activates menu item No. 40 to 45) ? YES, NO 40 ARCP Autopilot Remote Control Panel (ARCP) in front of ECDIS ? YES, NO 41 ChanPos Interface No. of position receiver 3, 4, 5, 6 42 Ecdisdialog Interface No. of ECDIS 3, 4, 5, 6 Autopilot NP2035 Autopilot Service Manual 1--37 Edition: 1 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 43 Pos.type NMEA sentence of position data. For W1 operation GGA must be selected GGA, GLL 44 Postimeout Defines position timeout interval for track cancelation at NP 2035 5, 10, 20, 30, 40, 50 60, 90, 120, 180, 240 45 ACTPAR Setting track control parameters (activates menu item No. 47 to 88) ? YES, NO 46 ACTCrseCtl Activates a special Course Controller used to calibrate the track controller ON, OFF 47 ExtShpP (Extra Ship Pa- rameters) Setting extra ship parameters (activa- tes menu item No. 48 to 52) ? Description for the parameters No.48 to No. 52: Extra ship parameters are parameters characterizing the ships behavior and therefore the control performance of the autopilot. Independent from the current values of counter rudder, rud- der and ships length they are only for use during track control and are not influenced by any other operator in- put. These parameters allow to cali- brate the track controller indepen- dently from the course controller YES, NO 48 CR_act Counter rudder 0.0, 0.5, ..., 5.0, 5.5, ..., 9.0 49 R_act Rudder -3.0, -2.5, ..., 0.0, 0.5, ..., 5.0, 5.5, ..., 9.0 50 LoadInflce If activated the parameters of the track controller CR_act, R_act are in- ternally influenced by the load input ON / OFF 51 ShipL_act (Ships Length) Ships length in meters 20, 25, 30, ..., 100, 110, ..., 200, 220, ...300, 350, 400, 500 52 ExtShpP Extra ship parameters active (swit- ched ON/OFF) ? (activates the function of parameters No. 48 to No. 52) If NO, the heading control parameters are taken. ON, OFF Autopilot NP2035 Service Manual 1--38 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 53 ExtYawP (Extra yawing pa- rameters) Setting extra yawing parameters (activates menu item No. 54 and 55)? Description for parameters No. 54 and No. 55: Extra yawing parameters are parame- ters influencing the controller band- width of the autopilot. They are only for use during track control and are not influenced by any other operator input. These parameters allow to cali- brate the track controller indepen- dently from the course controller. YES, NO 54 Yaw_act Yawing --1.0 ... 2.0 ... 11.0 55 EconDYaw Value which is added to Yaw_act in economy mode. Example: Normal yawing is set to 2, ExtYawP is set to 0.5. If now economy mode is selected, the yawing is set to 2.5. 0.0 ... 0.5 ... 4.0 56 ExtYawP Extra yawing parameters active (switched ON/OFF)? (activates the function of No. 54 and No. 55) If ON yawing is not taken from the current operation unit valve ON / OFF 57 TrckCtlP Setting parameters for track control (activates menu item No. 58 to No. 65) Y / N 58 PivotPt Distance (in meters) from the ships position reference point (normally the bridge) to the turning point of the ship (approximately the bow). Increasing (decreasing) this value the wheel-- over--point will be earlier (later) Analyzing method: Track change maneuver >45, radius <1.0 NM. Try both directions (PORT/STBD maneuver). If the ship starts the turn too early and stays in- side of planned track, decrease value. If the ship starts too late and stays outside the planned track, increase the value. --100, --90, -50, -40, -30, ..., 0, 10, ..., 100, 110, ..., 200, 210...., ....490, 500 Autopilot NP2035 Autopilot Service Manual 1--39 Edition: 1 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 59 TPosfilt Time constant (in s) of the internal position filter (not applicable when using RAYTHEON W1 ECDIS) Using a non--RAYTHEON ECDIS, the time constant of possible position fil- tering in the ECDIS + time constant for position filtering in the autopilot NP 2035 is approx. 50 s. 10, 20, 30, 40, 50, 60, ... 200 60 ApprRadDef Default radius (in NM) for track enter- ing maneuver to preplanned track in case of no additional information on the ECDIS interface. 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, ..., 2.0 61 GPSJmpOn Only when a jump in a GPS position signal gets bigger than this value (in meters) it is treated by the track con- troller as a position jump. This value has to be adapted to the behavior of the jump detection of the ECDIS (not applicable when using RAYTHEON W1 ECDIS) 100, 110, 120, ..., 200, 210, ..., 400, 9999 62 GPSJpOff When a detected jump in a GPS posi- tion signal gets smaller than this value (in meters) it is treated by the track controller as over. This value has to be adapted to the behavior of the jump detection of the ECDIS (not applicable when using RAYTHEON W1 ECDIS) 50, 60, 70, ..., 100, 110, ..., 400, 9999 63 DGPSJmpOn Only when a jump in a DGPS position signal gets bigger than this value (in meters) it is treated by the track con- troller as a position jump. This value has to be adapted to the behavior of the jump detection of the ECDIS (not applicable when using RAYTHEON W1 ECDIS) 10, 11, 12, ..., 20, 21, ..., 40, 9999 64 DGPSJpOff When a detected jump in a DGPS position signal gets smaller than this value (in meters) it is treated by the track controller as over. This value has to be adapted to the behavior of the jump detection of the ECDIS (not applicable when using RAYTHEON W1 ECDIS) 5, 6, 7, ..., 10, 11, ..., 40, 9999 Autopilot NP2035 Service Manual 1--40 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 65 MaxDRTime Maximum time (in sec.) the track con- troller works with an internal dead reckoned position while detecting a jump in the position input signal. This value has to be a bit bigger (about 10 sec) than the value the ECDIS allows for position jumps and after which track control is interrupted by the ECDIS (not applicable when using RAYTHEON W1 ECDIS) 10, 15, 20, ..., 40, 45, ..., 120 66 SpecialP Setting special parameters? (activates menu item No. 67 to No. 88) Y / N 67 LdaFunc Selection of a predefined or a userde- fined relationship (function) between the current yawing value and the lambda used by the track controller. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! Predef, User- def 68 LdaFNr No. of a predefined relationship (func- tion) between the current yawing value and the lambda used by the track controller. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 1, 2, 3 69 LdaFact Factor which modifies a predefined relationship (function) between the current yawing value and lambda 0.010, 0.013, 0.018, 0.024, 0.032, 0.042, 0.056, 0.075, 0.10, 0.13, 0.18, 0.24, 0.32, 0.42, 0.56, 0.75, 1.0, 1.3, 1.8, 2.4, 3.2, 4.2, 5.6, 7.5, 10, 13, 18, 24, 32, 42, 56, 75, 100 Autopilot NP2035 Autopilot Service Manual 1--41 Edition: 1 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 70 LdaLow Parameter for a userdefined relation- ship (function) between the current yawing value and lambda. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.0010, 0.0013, 0.0018, 0.0024, 0.0032, 0.0042, 0.0056, 0.0075, 0.010, 0.013, 0.018, 0.024, 0.032, 0.042, 0.056, 0.075, 0.10, 0.13, 0.18, 0 24 0 32 71 LdaUp ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.24, 0.32, 0.42, 0.56, 0.75, 1.0, 1.3, 1.8, 2.4, 3.2, 4.2, 5.6, 7.5, 10, 13, 18, 24, 32, 42, 56, 75, 100, 130, 180, 240, 320, 420, 560, 750, 1000 72 LdaMin Minimum value for the lambda de- rived from the current yawing value. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.0, 0.0010, 0.0013, 0.0018, 0.0024, 0.0032, 0.0042, 0.0056, 0.0075, 0.010, 0.013, 0.018, 0.024, 0.032, 0.042, 0.056, 0.075, 0.10, 73 LdaMax Maximum value for the lambda de- rived from the current yawing value. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.075, 0.10, 0.13, 0.18, 0.24, 0.32, 0.42, 0.56, 0.75, 1.0, 1.3, 1.8, 2.4, 3.2, 4.2, 5.6, 7.5, 10, 13, 18, 24, 32, 42, 56, 75, 100, 130, 180, 240, 320, 420, 560, 750, 1000, 9999 Autopilot NP2035 Service Manual 1--42 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 74 LdaEcDYaw Offset which is added to the current yawing value before calculating the lambda for the economy mode in track control. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! -2.0, -1.5, -1.0, -0.5, 0.0, 0.5, 1.0, 1.5, 2.0 75 JmpDetMthd Methode of positiv jump recognition. ONLY FOR USE BY DEVELOPMENT DEPARTMENT1 1 ... 3 ... 5 76 CheckT Value (in m/s) the ships speed has to change to make the track controller adapt its parameters to this new speed. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, ..., 3.0 77 WorkBeat Time (in sec.) after which the track controller adapt its parameters to the current speed in any case. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 5, 10, 15, 20, 25, 30 78 DitherAmp Amplitude (in degrees) of a special dither signal the controller adds to the set rudder, in order to counteract the rudder deadzone. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.0, 0.1, 0.2, 0.3, 0.4, ..., 1.0 79 Crs.quant Value (in degrees) the ships course has to change to make the track con- troller add the special dither signal (see No. 78) to the set rudder. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.0, 0.05, 0.1, 0.2 80 Qhf_min Minimum value of the relative ampli- tude of the course signals HF--part calculated by the autopilots seastate identification. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.1, 0.2, 0.3, ..., 1.0 81 Qhf_max Maximum value of the relative ampli- tude of the course signals HF--part calculated by the autopilots seastate identification. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.5, 1.0, 1.5, ..., 10.0, 11.0, 12.0, ..., 20.0 82 WhF_min Minimum value (in rad/sec) of the waves frequency calculated by the autopilots seastate identification. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.1, 0.2, 0.3, 0.4, ..., 2.0 Autopilot NP2035 Autopilot Service Manual 1--43 Edition: 1 3578E/102--886/885.DOC032 No. Adjus- ted Possible Setting (Default value is underlined) Significance Parameter 83 Whf_max Maximum value (in rad/sec) of the waves frequency calculated by the autopilots seastate identification. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 0.1, 0.2, 0.3, ..., 1.1, 1.2, ..., 2.0 84 PivotRange (for future use) 0, 10, 20, 30, ..., 60, 70, ..., 200 85 OS-PosFilt If activated (ON) the track controller uses a slightly overshooting internal position filter. If deactivated (OFF) a non-overshooting filter is used. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! ON / OFF 86 Drift_Reset After track change the drift is set to the values before track change. ONLY FOR USE BY DEVELOPMENT DEPARTMENT! ON / OFF 87 v_t_max Limitation of T*v (= T0*l) used for cal- culation of the intermediate segments inside the trajectory generation. ONLY FOR USE BY DEVELOPMENT DEPARTMENT ! 100, 120, 140, ..., 240, 260,... 400 88 maxTrErr Maximum track error which is taken into account for feedback during track control. ONLY FOR USE BY DE- VELOPMENT DEPARTMENT ! 100, 150, 200, ..., 1000 89 EeProm Which parameter values should be used ? UserDef The parameter values defined by the operator Default The default parameter values UserDef, Default 90 Writmem (Write memory) Should the current configuration changes be saved? YES The configuration changes will be saved. A restart will be performed. The autopilot will works with the new parameter values. NO Configuration changes are not taken into account. The last settings remain valid YES, NO Autopilot NP2035 Service Manual 1--44 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.5 Configuration DC Solenoid valve (24V Operation only) This configuration guarantees the correct polarity of the solenoid valve control. The polarity of the solenoid valve control is specific to the ship (refer to ships Steering Control Plans). Direct AC Valve control is not possible. 1.6.5.1 DC Solenoid Valve Control with Common Negative Connection COMMON COMMON + -- Configuration Bridge STBD Solenoid Valve II PORT Solenoid Valve II CONTROL 2 + -- CONTROL 1 D3B D4B D1B D2B MOSFET-- Switch MOSFET-- Switch MOSFET-- Switch MOSFET-- Switch I/O PCB 102--880.100 Backplane 102--880.10 COMMON STBD Solenoid Valve II Configuration Bridge PORT Solenoid Valve II L2.1 L2.2 L2.3 L2.4 L2.5 L2.6 L2.7 L2.8 L2.9 L2.10 L2.11 L2.12 1.6.5.2 DC Solenoid Valve Control with Common Positive ConnectionCOMMON COMMON Configuration Bridge STBD Solenoid Valve II PORT Solenoid Valve II CONTROL 2 COMMON + -- Configuration Bridge STBD Solenoid Valve I PORT Solenoid Valve I CONTROL 1 D3B D4B D1B D2B + -- MOSFET-- Switch MOSFET-- Switch MOSFET-- Switch MOSFET-- Switch I/O PCB 102--880.100 Backplane 102--880.10 L2.1 L2.2 L2.3 L2.4 L2.5 L2.6 L2.12 L2.11 L2.10 L2.9 L2.8 L2.7 Autopilot NP2035 Autopilot Service Manual 1--45 Edition: Dec. 04, 2002 3578E/102--886/885.DOC032 1.6.5.3 AC Solenoid Valve Control with additional relais Example only: AC AC external relais contacts 250VAC, 45VA + 24 V Port I II Stb Port Stb Autopilot NP2035 Service Manual 1--46 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 1.6.6 Calibration of the magnetic Sonde 1.) After installation and connection of the Sonde, select in the NP2035 Autopilot configuration No.13 Magnet YES, No.14 Magnet Source C.PCB (see section 1.6.4.4.). 2.) Select MAGNETIC heading on NP2035. TMC REF Fail alarm may be indicated on the display. 3.) Voltage U ref (AC) on R1 to R2 has to be appr. 1.8 V eff(400Hz) . 4.) Connect a voltmeter (DC range) to TP 13 (TP14) and TP 1 (GND) of NP2035 I/O--PCB. 5.) Turn the Sonde in its support until you read on the meter a voltage maximum between +3.8V to 4.3V. 6.) If the voltage is <+3.8V or >+4.3V adjust with potentiometer R41 REF.MAG. 7.) In case the voltage is not adjustable with potentiometer R41, the Sonde has to be altered closer to or further from the Magnetic compass. 8.) After distance alteration, repeat the voltage adjustment with Potentiometer R41 until TMC REF Fail disappears. 9.) Thereafter adjust the Sonde in its support until the Autopilot display shows the same heading values as the Magnetic Compass and tighten the Sonde. The potentiometer R59 SCALE SIN is for factory adjustment only! In case it was disadjusted by fault, readjust as follows: Turn the Magnetic Compass Card with an iron tool to 45 card reading. With this voltage an TP 13 to TP 1 and on TP 14 to TP 1 of the NP2035 I/O--PCB has to be the same ma- gnitude. If not readjusted with potentiometer R 59. Autopilot NP2035 Autopilot Service Manual 2--1 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2 Care, Maintenance, Repair and Spare-parts Catalogue 2.1 Safety Instructions Warning! This systemdoes not have asafety lockingdevice. Inthe opened unit there is dangerous voltage accessibility. Before carrying out maintenance or repairs, make sure the voltage is turned off and secure against inadvertent switching--on. ATTENTION Observe handling regulations! Electrostatic sensitive components CAUTION Handling of electrostatically sensitive semiconductor components Static voltages can damage certain semiconductor assemblies used within the system. The following safety precautions should therefore be observed when these components or units are being taken out of the system as they are then in danger of being damaged by static charges due to open inputs of the semiconductor components. 1) Persons removing units from this system must be grounded by a wrist band. The wrist band must lead via a ground cable to a central ground point in the system. 2) When using a soldering iron during repairs, the tip of the device must be used with a low voltage supply and grounded. The iron must be separated from the mains by a doubly insulated transformer. 3) Clothes must not produce any static charging. 4) Printed wiring boards that are fitted with these components must be stored and transported in anti--static containers. Autopilot NP2035 Service Manual 2--2 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Warning! Caution during maintenance and repairs: Avoid contact with live electrical circuits! All relevant safety regulations such as, e.g. VDE, VGB4, OSHA 1919 and other relevant safety standards must be observed. Caution! Maintenance and repairs must only be carried out by trained and qualified personnel with knowledge of the safety regulations for electrical devices. Removal or insertion of a subgroup or a printed wiring board with live voltage can lead to severe damage. Never insert fuses with other values than those stipu- lated! Autopilot NP2035 Autopilot Service Manual 2--3 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.2 Care and Maintenance 2.2.1 Care The NP2035 system does not require any care. 2.2.2 Maintenance The NP2035 system is maintenance free. Autopilot NP2035 Service Manual 2--4 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.3 Repairs 2.3.1 Removing the Cover of the Control Unit (see dimensional drawing 102--885.HP006/HP007) 1. Remove the small cover on top of the case. 2. Disconnect the flat cable connection from the PCBs. 3. Remove the screws (see drawing below). Remove screws marked with an arrow Control Unit (front view) Control unit (view from the top, cover removed) I/O Manager II CPU PCB I/O PCB Backplane Terminal Boards Fuse 2A (slow) Autopilot NP2035 Autopilot Service Manual 2--5 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.3.2 Replacing a PCB The PCBs contained in the assembly are specific to each system. After replacement, the following PCBs must be configured to the particular system and/or adjusted: -- CPU PCB 102--885.101 (see section 2.4.4) Figure below shows the complete equipping of an assembly with the maximum number of PCBs. These are: Control unit (view from the top, cover removed) CPU PCB I/O PCB Backplane Terminal Boards I/OManager II Fig. 2--1: An Assembly with a maximum number of PCBs. Replacing a PCB To replace a PCB, follow the instructions below: -- loosen the fixing screws -- pull at the same time on both lever handles -- if there is a jumper or configuration switch on the new PCB, then make sure it is set identically to that of the defective PCB -- push the PCB into the slot until the lever handle is locked in place -- tighten the fixing screws Autopilot NP2035 Service Manual 2--6 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.3.3 Fuse Replacement Caution In opened devices or desks, voltages representing a risk of electic shock are applied. -- Safety Instruction -- As a matter of principle, the system is to be made dead when installation or repair work is performed oan the equipment as well as during disassembly/assem- bly of components or during alteration of the circuitry. The device is protected against EMI and false poarity from the ships mains on the pri- mary side by a noise filter and a 2A slow--blow fuse . Attention: In case of false polarity of the main power, the fuse blows up. The 2A slow--blow fuse is on the right side of the terminal board (see figure below). -- Switch off the ships mains supply before replacing the fuse. -- The fuse holder can noe be opened (with a screwdriver). -- Replace the defective fose by a 2A slow--blow fuse. -- Fix the cap of the fuseholder (use a screwdriver). -- The ships mains supply can now be turned back. Autopilot NP2035 Autopilot Service Manual 2--7 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Autopilot NP2035 Service Manual 2--8 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.4 Significance of LED signals 2.4.1 CPU PCB 102--885.101 LED RUN Flashes (cicle time 1 sec) PCB functioning without disturbance. dark Signals a programme disturbance Actuate the RESET KEY, Program will be restarted. The PCB has to be replaced, when the LED is dark. LED FAULT out PCB functioning without disturbance. lit PCB not functioning (STOP) Press Reset switch to restart the program The PCB has to be replaced, when the LES lits up. Reset LED RUN (green) LED FAULT(red) 2.4.2 I/O PCB 102--880.100 Component side PC--Board 102--880 green LED red LED Green LED flashing: Program running (normal operation) Green LED ON or OFF malfunction Red LED out: no disturbance Red LED lit: PCB malfunction (Halt) Component side PC--Board green LED (flashing) red LED (malfunction) 1 2 3 4 1 = P2 Stb 2 = P2 Port 3 = P1 Stb 4 = P1 Port Offset Scale Ref. Mag Follow Up steering LEDs Autopilot NP2035 Autopilot Service Manual 2--9 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.4.3 I/O--Manager 102--885.100 LED RUN Flashes (cicle time 1 sec) PCB functioning without disturbance. dark Signals a programme disturbance Actuate the RESET KEY, Program will be restarted. The PCB has to be replaced, when the LED is dark. LED FAULT out PCB functioning without disturbance. lit PCB not functioning (STOP) Press Reset switch to restart the program The PCB has to be replaced, when the LES lits up. Reset LED RUN (green) LED FAULT(red) Autopilot NP2035 Service Manual 2--10 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.4.4 Configuration of the CPU PCB (see Configuration sheet CPU--PCB 68302 102--885.101) A new set of E--PROMS is only operational after the implementation of a COLD START (as mentioned below)! COLD START COLD START is triggered via DIP SWITCH B8 . -- Power OFF -- Pull out respective PCB -- place DIP SWITCH B8.7 to ON -- push the CPU PCB into the assembly (slot A1) until the lever handle is locked in place. -- switch power 2 seconds to ON than back to OFF -- pull the CPU PCB out of the assembly and place DIP SWITCH B8.7 to OFF. -- push the CPU PCB into the assembly (slot A1). Power ON again. On changing the CPU PCB, the system and the ships specification NP 2035 configuration will be lost! The NP2035 configuration has to be re--entered via the configuration selection MODE: Para function MODE: Change. ATTENTION In the configuration mode no alarm will be shown. The setting of the ships parameters in configuration mode should take place at the quay (dock side). Autopilot NP2035 Autopilot Service Manual 2--11 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.5 Spare Parts Catalogue See also spare parts catalogue at the end of this manual. 2.5.1 Notes on Ordering To ensure fast processing of replacement parts orders and to make sure that the correct replacement part is delivered, the following details are required: 1. Name of the ship 2. Raytheon Anschtz order number: e.g.: 610 0 61637 3. Device type (refer to type label) that the replacement part is required for: e.g.: Amplifier Box, Type 131--037 NG010. 4. Exact designation of the replacement part from the specifications given in the replacement parts catalogue Example: Stock No. Designation Drawing No. 1.607 172 Screw M 4x10 DIN 7985 A4 5. Required number of parts Autopilot NP2035 Service Manual 2--12 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 2.6 Technical Data 2.6.1 Electrical Specifications / Environmental Conditions Operator unit: power consumption : 12W supply with protection against pole confusion: 24VDC type of enclosure: IP 44 or IP 56 (extra case) ambient temperature for the desk mounting: -- 15 .. + 55 ambient temperature for the fly bridge: -- 25 .. + 70 Control unit: connection voltage 24VDC power consumption when using one operator unit: 25W type of enclosure: IP 23 (with protecting cap) ambient temperature: 0 to + 55 relative humidity IEC 945: 93% at 40 C EMC: see declaration of conformity output for the steering gear: -- switching output (2x) 24VDC 2A -- analog output (2x) max. set rudder value 10VDC; max. 5mA connection possibilities for external FU control -- FU control amplifier 400/460V 50/60Hz (from the main pump--switch box) R.o.T. control via the tiller: R.o.T. max. (35......90)/min to scale Autopilot NP2035 Autopilot Service Manual 2--13 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 interfaces for possible sensors: -- gyro compass with transmission system: ANSCHTZ course bus system ANSCHTZ step system (SYNCHRO 1 in preparation) 6 steps per degree -- magnet compass with transmission system:ANSCHTZ scanning probe or serial CRS--Bus -- ships log: 200 pulse or with NMEA 0183 interface (VHW,VTG) -- NAV systems position receiver, NAUTOPLOT, ECDIS interfaces for system expansion: -- R.o.T. Tiller possible -- Remote Tiller FU, NFU, Override -- max. 15 operating units or Remote Tiller potential free alarm and signal output for the supply of an external signal transmitter: -- alarm outputs (potential free): system alarm (disturbance in NP2035) off heading alarm, heading monitor alarm (with magnetic compass) -- status outputs track on MAGNET compass selected R.o.T. Tiller selected -- signal output: serial output RS232 for ANSCHTZ digital repeater display (set course, actual course, speed, Rate of Turn*) * When there is no Rate of Turn sen-- sor, the calculated R.o.T. is supplied via the compass selected by the NP2035 or further nav. outputs, see telegram specification. Autopilot NP2035 Service Manual 2--14 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 ALARM LEVEL OUTPUTS ALARM LEVEL 1 ALARM LEVEL 2 Designation Terminal Designation Terminal SYS FAIL L1.49..51 OFF heading and/or Heading Monitor L1.52..54 Operator Unit Failure L1.52..54 Heading Monitor L1.55..57 OFF HEADING L1.58..60 RoT--Tiller ON L1.61..63 Override ON L1.61..63 Track ON L1.64..66 Magnet ON L1.67..69 Tiller defective L1.67..69 Remote Tiller active L1.70..72 Autopilot NP2035 Autopilot Service Manual 3--1 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3 Constructional features of the NP2035 Autopilot system 3.1 Basic System The autopilot system is comprised of the following components (see Fig. 3--2:) Operator unit The control unit is suitable for installation in bridge desks, steering stands or for installation in a swivel housing: Control Unit The main components of the control unit are: -- a rack serving as central assembly housing for various electronic PCBs -- the backplane for EMV and internal connections -- the terminal connection block for ships wiring 3.1.1 Operator Unit The Operator Unit is the interface between the connection unit, the steering control and the connected periphery devices. There are various PCBs within the Control Unit. A rack is used for housing the assemblies. The operator unit is designed for installation in a control desk. General operation is via inscribed membrane keys which are subdivided into two groups: -- Command keys for selection of the operating mode. -- Function keys for individual adaptation Several of the silicon keys are equipped with an LED display: -- when the LED is lit this means, the key and the corresponding function has been chosen. -- when the LED flashes this means, a system message (alarm, warning, value acceptance) is waiting and has to be acknowledged. A rotary knob with a double function for the desired heading setting allows -- a direct desired heading adjustment that will be immediately effective -- a desired heading setting which will only be effective after activating the SET key. Autopilot NP2035 Service Manual 3--2 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Two inscribed status indicators with their own LED display display which compass has been selected. The display section of the operating unit consists of: a 4 digit Heading display for the heading reading with resolution to1/10 degree. -- an alphanumeric line which can be used as a text line or a bar graph display -- a 3 digit Preset Hedaing display for setting the desired heading -- a one digit display that shows the currently used parameters. 3.1.1.1 Function of Operation Unit Command keys Command keys determine the operating mode of the NP2035 Autopilot. Command key for the operating mode HEADING CONTROL (COURSE CONTROL) Command key for the operating mode TRACK CONTROL* Command key for the operating mode RATE OF TURN CONTROL* Command key for presetting of the heading change manoeuvre -- by a definite radius value -- by a definite R.o.T limit value * These operating modes are only selectable in connection with extended system environments (navigation receiver, R.o.T. Tiller). In case of an NP2035 system with many NP2035 control units, the command keys are used for switching over between the control locations. The switch--over ensures via the command keys of the chosen control unit: -- in the same operating mode, the preset desired heading remains unchanged -- on changing the operating mode, a set heading adaptation results and the set heading corresponds to the heading. Autopilot NP2035 Autopilot Service Manual 3--3 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Function keys --Parameter Management-- The parameter management will optimally adjust the autopilot to -- the relevant type of vessel -- the external conditions (wind, currents and yawing) -- optimize the control conduct Parameter group: A parameter group consists of the parameter values for YAWING, RUDDER and CNT.RUDDER. Up to a total of 6 parameter groups can be formed within the parameter administration. These can then be called up and can perform control functions as required. The parameter administration is also used for setting the limit values that support safe ship guidance during heading or track regulation. Function keys: Key for display and selection of possible sensors Key for display or selection of various limit value parameters Key for overlaying information during heading or track regulation (alphanumeric line and /or bar graph) Select Key for opening or modifying a parameter group Key for calling up a parameter group Autopilot NP2035 Service Manual 3--4 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 General Function Keys General function keys are used in setting and changing parameter values and acknowl- edging actions and alarms. Key for acknowledging a current alarm message and viewing the stored alarm messages. Key for acknowledging particular inputs, e.g. changes in parameter val- ues, changes in the preset heading. Multi--functional keys for dimming the illumination, modifying parame- ter values, selection and for the display test. Rotary knob for presetting of preset heading; has two setting possibilities: -- the presetting of the preset heading is only effective after pressing the SET key -- the presetting of the preset heading is immediately effective on turning the depressed rotary knob. According to the setting (>180 ) the ship will follow turning direction of the rotary knob (within 360 ). Set Display The control unit is equipped with three 7 segment displays and one alphanumeric line. Always display the ACTUAL HEADING Heading Preset Heading always display the preset heading Automatically display an alarm message in plain text. Can be set to the following constant display: Man: + 17, 2 kts Heading: 098,0 Setrudder: P 10 XTE: | 0.29NM tendency display for the preset heading and heading deviation manual speed preset heading with 1/10 display track deviation in NM current set rudder displays the control attribute displays the parameter group currently in memory or Autopilot NP2035 Autopilot Service Manual 3--5 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Status Displays The status displays are as follows: this status display indicates that Gyro Compass is selected this status display indicates that Magnetic Compass is selected this status display is for Remote Operation. The preset heading is set via an external navigational system. In combination with this option, the following operating possibilities of the NP2035 are blocked: -- command keys -- selection of heading change maneuver (radius or R.o.T.) -- rotary knob functions Autopilot NP2035 Service Manual 3--6 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3.1.2 Control Unit The connection unit (see Fig. 3--1:) mainly consists of: -- I/O--PCB with Power supply and Follow--up steering (switching and analog) -- CPU--PCB -- I/O--Manager PCB -- Backplane -- Terminal block The equipment of the Control Unit depends on the system type. Optional expansion capability for an external follow--up control. The construction of the Operator Unit, as well as the respective PCB functions, are doc- umented in the accompanying descriptions; Steering control amplifier, switching Type 139--152 E01 Steering control amplifier, analog Type 139--153 E01 The assemblies are fitted with various electronic PCBs; their operation modes are as follows: CPU--PCB (central processor unit) general data administration within the system. control area: heading control track control RoT control administration of user inputs. administration of the external data information of the navigation receiver or of the multifunction display. general system monitoring in the form of an LED signal on the PCB or as a plain text message within the alphanumeric display of the operator unit. I/O--PCB (input / output) The PCB is designed for reading in/out of several signals. Follow--up control with switching and analog output Power supply (DC/DC converter) Input Reading--in of possible external signals -- pulse log (200 P/NM) -- speed (NMEA 183/ VHW/ VTE) -- course bus (NMEA 183 / HEHDT/ GPHDT) -- rate gyro -- R.o.T. -- Tiller -- actual rudder Autopilot NP2035 Autopilot Service Manual 3--7 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Reading--in of possible external status signals -- override Tiller -- steering control knob AUTO / HAND / REMOTE Output -- set rudder output -- status signals -- alarm signals I/O PCB -- with follow--up function (standard) The I/O--PCB is used for controlling the steering gear with solenoid switching For steering gears with proportional solenoid valves the I/O PCB has two galvanically free outputs with +/-- 10V max. During the rudder positioning control, the rudder set value and the rudders actual value are continually compared. Control errors are transmitted to the steering gear in the form of switch or analog signals. If the navigation system is not equipped with a GyroStarII / STD20 / STD22 system (course bus), a NMEA 183 HEHDT (GPHDT) or a step system can be used as heading input. I/O Manager The I/O--Manager II is a interface between the Autopilot NP2035 and a connected ECDIS. Data communication takes place through ths I/O--Manager (serial interface) with bidirectional communication between both systems. Example of an NP2035 connection unit as stand--alone model Connection unit (front view) Fig. 3--1: Control Unit -- Survey -- Autopilot NP2035 Service Manual 3--8 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 Rudder Ruder position-- feedback unit Steering gear (switch/analog)) Control Unit NP2035 possible peripheries -- NAV receiver/position receiver -- Gyro compass -- Magnet compass -- Digital multi--functional display -- Control selector switch -- R.o.T. Tiller -- Log sensor (serial/pulse) -- Rate gyro -- STD 20 course bus -- Series Navigation system -- External Status signal for Heading Error Alarm Track On Magnet Sensor On R.o.T. Control On -- Remote Tiller (bus control) Alternative, external follow--up control External Control Unit Type139152 E01 Autopilot Connection Unit 102--885 -- FU--Tiller -- Hand wheel Does not belong to the NP2035 system HAND AUTO STANDARD 20 PLUS Control Unit Gyro system 102--886 Remote Tiller optional Remote Tiller (steering components) Data distribution bus ECDIS Track Control System Fig. 3--2: Basic system of Autopilot NP60 Autopilot NP2035 Autopilot Service Manual 3--9 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3.2 Monitoring Functions of the NP2035 The NP2035 system is fitted with a complex monitoring function which allows both internal and external irregularities to be recognized. A system message (s. Operator Manual Chapter. 2.14 ) is generated in case of distur- bances or errors; this message is displayed in plain text on the text line. 3.2.1 Monitoring the Heading Controller Individually adjusted limit values (heading alarm thresholds) monitor the control devi- ation and trigger a heading error alarm when these are exceeded. Heading monitor and off heading function The heading monitoring function is always executed in conjunction with the MAGNET compass. The magnet compass heading is checked against the preset heading to make sure that it keeps within the set course alarm thresholds. If the threshold is exceeded, the heading monitor alarm (external alarm -- relais contact) is triggered. The off heading function compares the difference of the Gyro Compass and the preset heading. If the threshold is exceeded the off heading alarm is triggered. This alarm is indicated on the panel and available as external relay contact. 3.2.2 Monitoring the Serial Data Transfer A check is made here as to -- whether data transmission is interrupted -- the data format of data transmission -- the valid character and/or the checksum 3.2.3 Plausibility Monitoring of the Connected Periphery Devices Here, the system parts are continually checked for disturbances. -- MAGNET compass -- GYRO compass -- LOG sensors -- navigation receiver -- external autopilot system -- steering gear Autopilot NP2035 Service Manual 3--10 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3.2.4 Monitoring the Control Unit PCB faults are shown via corresponding LEDs on the front face of the card (see section 2.4). Autopilot NP2035 Autopilot Service Manual 3--11 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 3.3 NMEA 0183 Format NMEA 0183 Format VTG VTG Course Over Ground and Ground Speed Talker $-- --VTG,x.x,T,x.x,M,x.x,N,x.x,K*hh<CR><LF> SOG, km/hr Speed, knots Course, degrees Magnetic Course, degrees True NMEA 0183 Format VBW VBWDual Ground/Water Speed Status, stern water speed, A= Data valid Stern transverse ground speed 1 , knots Status, stern ground speed A = Data valid $-- --VBW,x.x,x.x,A,x.x,x.x,A,x.x,A,x.x,A*hh<CR><LF> V = Invalid Stern transverse water speed 1 , knots Status, Ground speed, A= Data valid Transverse ground speed 1 , knots Longitudinal ground speed 1 , knots Status: Water speed, A= Data valid Transverse water speed 1 , knots Longitudinal water speed 1 , knots Notes: 1) Transverse speed: -- = port, Longitudinal speed: -- = astern Autopilot NP2035 Service Manual 3--12 Edition: Apr 12, 2002 3578E/102--886/885.DOC032 NMEA 0183 Format HNROT HNROT Rate of Turn (deg/min) $HNROT,(--)xxx.x<CR><LF> Rate of turn in degrees/min Direction of turn String format for rate of turn (deg/min) Talker identifier Start of sentence NMEA 0183 Format HEROT HNROT Rate of Turn $HEROT,x.x,A*hh<CR><LF> Rate of Turn, degrees/minute, -- bow turns to port Staus A = Data valid NMEA 0183 Format HEHDT HEHDTHeading, True $HEHDT,x.x,T*hh<CR><LF> eading, degrees True NMEA 0183 Format HEHDG HEHDG Heading, Deviation&Variation $HEHDG,x.x, , , , *hh<CR><LF> Magnetic sensor heading, degrees NMEA 0183 Format VDVHW VDVHW Water Speed $VDVHW, , , , ,x.x,N, ,*hh<CR><LF> Sped, knots Ersatzteilkatalog SPARE PARTS Autopilot NP 2015, NP 2025, NP 2035 Connection Unit Type 102--885 NG001, NG 002 CATALOGUE 14.610 RA/S--SU 0201 EDITION 01 1 All depicted items which are not mentioned in the text are not applicable for this unit. Since further developement may necessitate making modifications to existing equipment, its conformity with the relevant illustrations and drawings is not always ensured. Ratheon Marine will be under no liability whatever that may arise from any such differences. 1 in NG 002 2 2 pieces in NG 002 1 2 3 4 6 5 Pos. Lager--Nr. Stock--No. Benennung Designation Zeichnungs--Nr. Part--No. Stck. Qty. Herst.--Code MFRC Versorgungs--Nr. NSN 1 1 3.603 170 I/O Manager II I/O Manager 102--885.100 1 D2865 2 3.603 171 CPU--Karte 16 MHz 68k CPU PCB 16 MHz 68k 102--885.101 1 D2865 3 3.603 560 I/O--Karte Autopilot I/O PCB Autopilot 102--880.100 E01 1 2 D2865 4 3.603 059 Serielles UKM Serial Transfer Module NB 05--343 1 D2865 5 3.603 403 Backplane Autopilot Backplane Autopilot 102--880.10 E01 1 D2865 6 1.762 018 G--Sicherungseinsatz Fuse T2A L 250V IEC 127--2 1 D2865 5920--12--165--8042