Simrad TP10 / TP20 / TP30

TILLERPILOT
TP10, TP20 & TP30
SERVICE MANUAL
SIMRAD
Issue 4.0 17/09/03
Simrad Margate Ltd
Star Lane, Margate, Kent CT9 4NP,UK
Telephone +44 (0) 1843 290290
Facsimile +44 (0) 1843 290471
E-Mail : productsupportmargate@simrad.com
CONTENTS
1
INTRODUCTION
1.1
1.2
Electronic PCBs
Mechanical Components
2
OPERATION
3
ASSEMBLY INSTRUCTIONS
4
MECHANICAL ASSEMBLY DRAWINGS
5
CIRCUIT DESCRIPTIONS
6
CIRCUIT DIAGRAMS
6.1
6.2
Circuit Schematics
Component Lists and Layouts
7
PROGRAMMING AND CONFIGURATION
8
FAULT FINDING
8.1
8.2
9
SPARE PARTS DETAIL
9.1
9.2
9.3
10
Common User Faults
Common Technical Faults
Spares
Service Aids
Accessories
TECHNICAL NOTES
© 2003 Simrad Margate Ltd
The technical data, information and illustrations contained in this publication were to the best of our knowledge correct at the time of going to print. We
reserve the right to change specifications, equipment, installation and maintenance instructions without notice as part of our policy of continuous
development and improvement. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic or
otherwise without prior permission from Simrad Margate Ltd. No liability can be accepted for any inaccuracies or omissions in the publication, although
every care has been taken to make it as complete and accurate as possible.
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Tiller Pilot TP10, TP20 & TP30
Section 1
Introduction
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1
INTRODUCTION TO THE TP10, TP20 AND TP30 TILLERPILOT
The TP10, TP20 and TP30 Tillerpilots combine highly sophisticated electronics with advanced
software and powerful mechanical drive to provide accurate and reliable steering performance
under a variety of different conditions with minimal current consumption.
TP10 – is suitable for tiller steered sailing yachts up to 10M (34 Ft) in length.
TP20 – offers the same facilities as the TP10 and is fully compatible with the Navico Corus
instrument system to provide a complete navigation system. Options offered include connection to
an external compass, wind sensor or navigational receiver together with additional remote control
facilities.
TP30 – offers the same facilities as the TP20 with an improved re-circulating ball screw drive and
is suitable for tiller steered sailing yachts up to 12.8M (42 Ft) in length.
The main components of the Tiller Pilot are listed below:
Electronics PCBs
Early versions
TP10 PCB (TP10 only)
TP30 PCB (TP 20 & TP30)
Current Versions. The same PCB is used for all products. The wiring
loom carrying the NMEA data is left disconnected in the TP10.
TP10 / 20 / 30
Re-engineered PCB (Common to all)
Mechanical Components
General Assy : TP10
General Assy : TP20
General Assy : TP30
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Tiller Pilot TP10, TP20 & TP30
Section 2
Operation
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SIMRAD
OPERATING SIMRAD
This Service Manual only contains operating instructions for those features of the Simrad Tiller
Pilot range that are not normally available to the end user. For details of normal operation please
refer to the appropriate Simrad Instruction Manual.
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Tiller Pilot TP10, TP20 & TP30
Section 3
Assembly Instructions
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SIMRAD
ASSEMBLY INSTRUCTIONS
General Assembly : TP10
Motor and Drive Assembly. The Bottom Case Assembly is supplied fitted with appropriate
cables. Refer to detail in Drawing Number E03504 and insert the Push Rod Seal E00747, which
has a taper inner bore, into the case with the larger bore of the seal facing outwards. Fit “O” Ring
190026, spacer E02870 and End Cap E02495 and push home. Fit Retainer E03084 and secure
with 2 screws 200002 to hold the end cap, ensuring it is pushed fully in when the two screws are
tightened. Using a small brush, grease the ‘trough’ area and the bore which houses the seal, “O”
ring and spacer. Insert the Drive Assembly E03264 ensuring that the bearing slots into the bearing
housing and the drive belt 280027 is fitted around the pulley. Insert the Motor Assembly E02788
fitted with front and rear Motor Mounts E02502 and E02503 ensuring that the blue wire is
uppermost, the motor sits snugly into the bottom of the retaining slot and the drive belt is engaged
over the motor drive pulley. Check that the motor, belt and drive screw assembly move freely. Fit
Bearing Clamp E02497 on two Nylon Spacers 200115, one on each screw 200137, into the case
bottom and secure the bearing with the two screws. Refer to the sketch below and check that the
belt tension is within +/- 3mm.
Fit the Tiller Connector E02607 into the end of the Push Rod E02522 and screw in, finger tight.
Hall Effect PCB. Fit the Hall effect PCB onto the 2 pillars using 2 nylon washers 200037 as
spacers between the pillars and the PCB, and 2 screws 200139. Ensure that the separation
distance between the Magnets (E03208), seated in the 71 Tooth Pulley (E02505), and the Hall
Effect Devices (140010) does not exceed 1mm.
Main PCB. Feed the power, motor and feedback leads through the 2 grommets 190036 and the
appropriate grommet in the PCB Assembly cover and solder the connections to the PCB. Refer to
drawing and push PCB Assembly firmly onto the four bosses in the PCB Cover E02680. Clip the
compass Assembly E02637 into the Drilled PCB Cover E02680, it can only be fitted one way
round, ensuring that the lugs on the compass assembly line up with the 2 holes in the PCB cover
and push in. Refer to drawing E03504 and ensuring that the wires from the compass to the
connector lay over the PCB, insert plug into the socket on the PCB. Ensure all wires are clear of,
and not fouling the PCB cover seal, and position the PCB Cover complete with the PCB and
compass into the Case Top Assembly E02612. Screw down the PCB cover with 6 screws 200139
and fully tighten. Position the two grommets into case top, and push home into the two slots.
Wrap the ‘Wits” fixing 200196 around the cable loom, and using a screw 200139 fix into the top
cover.
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Main Seal. Fit the pivot pin into the square section at the rear of the prepared bottom case
ensuring that the pin hangs out of the case with the notch on the pivot facing towards the operating
rod of the tillerpilot. Fold the metal pin into its recess in the lower case. Position the Case Seal
E02498 onto the case bottom ensuring it is pushed fully into the grooved housing. Carefully lift the
case seal from around the area of the pivot pin and using a cotton bud apply Dow Corning 1205
Primer 260029 to the case. Fill a small hypodermic syringe with Dow Corning 3140 Silicone
sealant 260001 and run a small bead of sealant completely around the case seal in the area of the
square as shown below.
Refit the seal onto the case.
Final Assembly. Carefully position the case top onto the bottom ensuring that the case seal is
correctly located all round, squeeze the top and bottom halves of the case together, and fit the 10
screws 200088. Tighten down evenly all round in the sequence shown below:
Post Assembly Test. Remove the Tiller Connector E02607 and push the Tillerpilot Test Syringe
Part No. TP-SRY over the end of the Push Rod E02522. Depress the syringe piston and release,
the piston should return to its original position indicating that the integrity of the case seal has not
been compromised during fitting. Remove the Test Syringe and refit the Tiller Connector.
General Assembly : TP20
Refer to Drawing No. E03505. Assembly is identical to the TP10 with the following exceptions:
Case Bottom. The case bottom includes a third wiring (communications) loom to carry NMEA and
CANBUS data.
PCB Cover E02681. The PCB Cover is drilled with a third access point and grommet to accept
the NMEA and CANBUS data leads.
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General Assembly : TP30
Refer to Drawing No. E03506. Assembly is identical to the TP20 with the following exception:
Drive Assembly E02618. The Drive Assembly employs a re-circulating ball screw. The assembly
is held in place by the metal mounting plate sitting in the mounting slots in both top and bottom
cases and drive belt tension is adjusted by the inclusion of spacing shims E02754 as required.
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Tiller Pilot TP10, TP20 & TP30
Section 4
Mechanical Assembly Drawings
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4
MECHANICAL ASSEMBLY DRAWINGS
General Assembly : TP10
General Assembly : TP20
General Assembly : TP30
E03504
E03505
E03506
12
13
14
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Tiller Pilot TP10, TP20 & TP30
Section 5
Circuit Descriptions
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5
CIRCUIT DESCRIPTIONS
Tillerpilot Common PCB Assembly
Introduction. The PCB Assembly is a common item to all Wheelpilots and Tillerpilots. However,
when the PCB is used in the TP10 or WP10 those components concerned with NMEA and
CANBUS data are present but not in use, these components are highlighted in Red on the Circuit
Diagram Drawing No. E03372.
Supply and Regulation. The Tiller Pilots are designed to work from a 12 V source. Protection
against incorrect polarity is provided by D1 and D4. Capacitors C1and C3 are used as reservoirs
to hold up the supply voltage and reduce any supply dips. Protection against over-voltage spikes
is provided by Resistor R2 and Zener Diode ZD1 and Regulator REG1 provides a 5V regulated
supply. Transient Voltage Suppresser TVS1 protects the MOSFET drive transistors, TR10 to
TR13, from voltage spikes greater than +16V.
Microprocessor. Light Emitting Diodes LED1 to LED4 are driven from the microprocessor IC2
Ports P0.0 and P0.2 to P0.4 and turn OFF when the line goes HIGH via the transistor switches
TR2 to TR5. When the transistors are off, resistors R32, R34, R36 and R38 provide a low current
path for the LEDs to provide low level night illumination. The Audio Resonator AR1 is self
resonating and switches ON when Port P0.5 goes HIGH via the transistor switch TR1 and resistors
R59 and R60. The control key lines on Ports P4.0 to P4.4, normally pulled to +5V via resistors R7
to R11, are “scanned” by the microprocessor to detect if any of the switches have been operated
and pulled the line LOW.
NMEA Data In. NMEA data is optically isolated by IC5 and then fed into Port P2.4 of the
microprocessor. Transistors TR6, TR7 and TR8 and components D6, D7, D8, R17, R18 and R19
form a switch, protected from high voltages, driven from Port P0.1 of the microprocessor. The
switch is used to apply the synchronisation pulse (HR200_SYNC) to the NMEA line for products
employing a Hand (Remote) Controller.
CANBUS Data. CANBUS data in and out is driven by IC3 directly to and from Ports P2.1 and P2.0
respectively.
NB. Components shown in RED on the circuit diagram, Drawing No. E03372, are not in circuit
when the PCB is used with WP10 or TP10. The cable loom to connect them is absent from these
products.
Configuration Links. The Links, L1, L2 and L3, are used to configure the Microprocessor
to either Wheelpilot or Tillerpilot operation and to model versions 10, 20 or 30 in
accordance with the table below:
1
Model
TP 10
WP 10
TP 20
TP 30
WP 30
LEGEND
Link 1
N/C
N/O
N/C
N/C
N/O
Link 2
N/C
N /C
N/C
N/O
N/O
Link 3
N/C
N/C
N/O
N/O
N/O
N / C Normally Closed (soldered)
N / O Normally Open (unsoldered)
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Microprocessor Reset. Integrated Circuit IC6 is an integrated reset generator for the
microprocessor which produces a reset LOW pulse of approximately 50mS duration at switch on
and whenever a 5v supply failure occurs. In addition to the reset provided by IC6, the
microprocessor has a built in watchdog timer which will create a reset if a software crash occurs for
any reason.
Non-Volatile Memory (NVM). Integrated Circuit IC3 provides 1Kbit of E2 memory for the retention
of important data after power down.
Fluxgate (Compass). Two anti-phase signals are provided from microprocessor Ports P1.7 and
P1.6. These signals are buffered by TR15 and TR16 to provide a higher current drive to the
excitation coil of the fluxgate. A reference voltage level of +2 volts is provided by R46 and R53
decoupled by C53. The 2 coils, mounted at right angles, provide output signals proportional to the
sine and cosine of the Earth’s magnetic field. These signals are fed via the electronic switch IC9,
to 2 dual slope integrating analogue to digital converters IC7 and IC 8 plus associated
components. The outputs of the comparator IC7 are fed to the microprocessor Ports P1.4 and
P1.5 which provide input capture facilities. Accurate timing of the conversion is kept by the
microprocessor to provide simultaneous precision analogue to digital conversion of both sine and
cosine signals to avoid errors created by multiplexing the inputs.
Motor Drive. The motor drive signals (MDRIVE_A and MDRIVE_B) are generated from the
microprocessor at Ports P0.7 and P0.6, these lines being LOW when there is no drive and HIGH to
drive. The drive outputs control IC10 and IC11 which are comparators set at threshold levels of
+4V and +1V produced by the resistor network R71, R72 and R73. The comparators invert the
signals and provide the current to switch the MOSFETs in stages which prevents both P and N
channel MOSFETs on the same side of the “H-bridge” configuration, (i.e. TR10 and TR11 or TR12
and TR13), being partially switched on at the same time. When there is no drive, both N-channel
MOSFETs TR11 and TR13 are switched on giving a direct short across the motor to the 0V line
thus providing active braking
EMC. Capacitors with values of 100pF, 100nF and 1nF are extensively used to decouple noise
from switched data lines. Two A.C. coupled connections labelled “CHASSIS” , routed via
capacitors C63 and C64, were provided for interconnection to the internal metalwork for EMC
purposes. Tests have confirmed that connection is not required.
Hall Effect PCB.
Introduction. The Hall Effect PCB is a generic item which can be used for both Tillerpilots TP10,
TP20 and TP30 and Wheelpilots WP10 and WP30. For Tillerpilots, the Hall Effect devices are
mounted vertically into the PCB and horizontally for Wheelpilots. The circuit diagram for the Hall
Effect PCB is given in Drawing No. E03182.
Feedback. Two Hall Effect sensors HE1 and HE2 are mounted on the Hall Effect PCB and sense
the rotation of 2 small bar magnets mounted 1800 apart in the pulley wheel. This produces a
quadrature feedback output, at logic levels, FB1 and FB2. The PCB is powered from the host unit
+5V regulated supply, the line being filtered by C1, and signals FB1 and FB2 are fed back to the
microprocessor via pull-up resistors on the host unit PCB.
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Tiller Pilot TP10, TP20 & TP30
Section 6
Circuit Diagrams
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6
CIRCUIT DIAGRAMS
Circuit Schematics
Common PCB Circuit Diagram
Hall Effect PCB Circuit Diagram
E03372
E03182
Component Lists and Layouts
Common PCB Assembly Detail
E03178
Hall Effect PCB Assembly Detail
E03184
Early Version WP10 / TP10 Assembly Detail
Early Version WP30 / TP20/30 Assembly Detail
E03181
E03178 (Pre Iss. 6)
20
21
22
23
24
25
26
Tiller Pilot TP10, TP20 & TP30
Section 7
Programming and Configuration
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SIMRAD
PROGRAMMING AND CONFIGURATION
This Service Manual only contains programming and configuration information for
those features of the autopilot which are not normally available to the end user. For
details of normal programming and configuration please refer to the appropriate user
manual.
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Tiller Pilot TP10, TP20 & TP30
Section 8
Fault Finding
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FAULT FINDING
Common User Faults. Common user faults are included in the Diagnostics
Guide included in the user manual.
Common Technical Faults. None yet identified.
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Tiller Pilot TP10, TP20 & TP30
Section 9
Spare Parts Detail
31
9
SPARE PARTS DETAIL
Spares Packs
TPPK1
TPPK2
TPPK3
TPPK4
TPPK5
TPPK6
TPPK7
TPPK8
TPPK9
TPPK10
TPPK11
TPPK12
TPPK13
TPPK14
TPPK15
TPPK16
TPPK1 7
TPPK18
TPPK19
TPPK20
TPPK21
TPPK22
TPPK23
TPPK24
TPPK25
9.2
Accessories
TB30
TB60
TB90
TB120
PB30
PB60
PB90
CB1
PRE30
PRE60
PRE90
PRE120
PRE150
PRE300
9.3
TP10 / 20 MECHANICAL ASSEMBLY
TP10 TOP CASE
TP20/30 BOTTOM CASE
TP10 PCB CASE
WITHDRAWN
FLUXGATE ASSEMBLY
MOUNTING PIN, CUP AND CONNECTOR
MOTOR ASSEMBLY
FEEDBACK KIT
DRIVE BELT
CASE SCREW PACK
PUSH ROD SEAL PACK
CASE SEAL PACK
TP100 TOP CASE
GREY BOTTOM CASE
TP20 TOP CASE
TP20/30 PCB CASE
WITHDRAWN
WITHDRAWN
TP30 TOP CASE
COMMON PCB ASSEMBLY
TP30 MECHANICAL ASSEMBLY
TP300CX TOP CASE
TP200CX TOP CASE
TP10 BOTTOM CASE
TILLER BRACKET 30mm
TILLER BRACKET 60mm
TILLER BRACKET 90mm
TILLER BRACKET 120mm
PEDESTAL BRACKET 30mm
PEDESTAL BRACKET 60mm
PEDESTAL BRACKET 90mm
CANTILEVER BRACKET
PUSH ROD EXTENSION 30mm
PUSH ROD EXTENSION 60mm
PUSH ROD EXTENSION 90mm
PUSH ROD EXTENSION 120mm
PUSH ROD EXTENSION 150mm
PUSH ROD EXTENSION 300mm
Service Aids
TP-SRY
TILLERPILOT TEST SYRINGE
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Tiller Pilot TP10, TP20 & TP30
Section 10
Technical Notes
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PS 139
PS 140
PS 173
PS 174
SIMRAD
TECHNICAL NOTES
Identification of Tillerpilot variants
Improved bonding of drive pulley to motor drive shaft
Positioning of Feedback PCB
Re-engineered Main PCB
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Technical Note
FOR THE ATTENTION OF THE SERVICE MANAGER
NUMBER
:
PS 139
PRODUCT
:
Tillerpilot – TP100 / TP200CX /
TP300C / TP300CX / TP10 / TP20 /
TP30
SUBJECT
:
Identification of Variants
DATE
:
1 October 1999
There are a number of variants of Tillerpilots currently in use which, though
similar in appearance, are built and operate differently. Positive identification is
therefore essential when ordering spare parts to ensure that the correct item is
dispatched.
The main aids to identification are:
1.
Lack of a Hall Effect PCB indicates Back emf, earliest, version.
2.
Hall Effect PCB with microprocessor mounted in socket indicates
intermediate version.
3.
Hall Effect PCB with surface mount microprocessor indicates
latest version.
A table of variants identified by serial number and drawings, General Assembly,
PCB Assembly and Circuit Diagram, to aid identification of the different PCBs, is
given below:
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TILLERPILOT VARIANTS. The Tillerpilot variants can be conveniently divided into 3 groups:
1.
2.
3.
Feedback produced from the motor back emf.
Feedback produced from a Hall Effect PCB.
Introduction of Surface Mount microprocessor (SMu)
TP100
Back emf
TP200CX
Back emf
TP300C
Back emf
TP300CX
Back emf
TP100
Hall Effect
TP200CX
Hall Effect
TP300CX
Hall Effect
TP200CX
SM u
TP300CX
SM u
E02517
E02520
E02520
E02520
E03190
E03189
E03189
E03398
E03398
from
Start
Start
Start
MK3143
PE8818
PB1484
OD6415
to
PE8818
PB1483
MI2954
OD6414
Continue
Continue
Continue
Gen Assy
E02587
Not Issued
E02616
E02616
E03299
E03262
E03300
PCB Assy
E02515
E02518
E02518
E02518
E03181
E03178
E03178
Cct Diag
E02549
E02550
E02550
E02550
E03179
E03176
E03176
u No.
Man
Ser
No.
TP10
SM u
TP20
SM u
TP30
SM u
E03398
E03398
E03398
from
OL7635
OL1384
OL7190
to
Continue
Continue
Continue
Gen Assy
E03504
E03505
E03506
PCB Assy
E03181
E03178
E03178
Cct Diag
E03371
E03372
E03372
u No.
Man
Ser
No.
Not Yet In Production
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Technical Note
FOR THE ATTENTION OF THE SERVICE MANAGER
NUMBER
:
PS 140
PRODUCT
:
Tillerpilot – TP100 / TP200CX /
TP300C / TP300CX / TP10 / TP20 /
TP30
SUBJECT
:
Improved bonding of drive pulley
to motor drive shaft.
DATE
:
1 October 1999
The 20 Toothed Pulley Part No. E02839 is a push fit onto the motor drive shaft,
see sketch below, and the bonding is enhanced with Loctite 270 Part No.
260025. Instances have occurred where the bonding has weakened resulting in
reduced drive efficiency or operational failure. An improved bonding adhesive
Loctite 638 Part No. 260063 has been identified and approved for use. All
Tillerpilot repairs should be carried out using the new adhesive.
The new bonding agent has been used in the manufacture of all Tillerpilots with
the alphabetic prefix PC, 1 March 1999, and subsequent serial numbers. The
Product Support Department should be informed of any units found to be
slipping post production date 1 March 1999.
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