Ray Mechanical Linear Drive (M81130, M81131, M81132, M81133, M81134) Installation Instructions 81175

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Linear Drive
Installation instructions
English
Date: 03-2016
Document number: 81175-7-EN
© 2016 Raymarine UK Limited
M81130: Type 1 Linear Drive 12 V
M81131: Type 2 (short) Linear Drive 12 V
M81132: Type 2 (long) Linear Drive 12 V
M81133: Type 2 (short) Linear Drive 24 V
M81134: Type 2 (long) Linear Drive 24 V
81175_7.book Page 3 Monday, March 7, 2016 2:39 PM
4
Important information
Safety notices
EMC conformance
All Raymarine equipment and accessories are designed to the best industry standards for use
in the recreational marine environment. The design and manufacture of Raymarine
equipment and accessories conform to the appropriate Electromagnetic Compatibility (EMC)
standards, but correct installation is required to ensure that performance is not compromised.
Handbook information
To the best of our knowledge, the information in this handbook was correct when it went to
press. However, Raymarine cannot accept liability for any inaccuracies or omissions it may
contain. In addition, our policy of continuous product improvement may change
specifications without notice. As a result, Raymarine cannot accept liability for any
differences between the product and the handbook.
WARNING
Product installation
This equipment must be installed in accordance with the instructions
contained in this handbook. Failure to do so could result in poor product
performance, personal injury and/or damage to your boat.
Because correct performance of the boat’s steering is critical for safety,
we STRONGLY RECOMMEND that an Authorized Raymarine Service
Representative fits this product.
WARNING
Navigation aid
When this product is used within a navigation system, it is only an aid to
navigation. It’s accuracy can be affected by many factors, including equipment
failure or defects, environmental conditions and improper use or handling. It is
the user’s responsibility to exercise common prudence and navigational
judgements. This product should not be relied upon as a substitute for such
prudence and judgement. Always maintain a permanent watch so that you can
respond to situations as they develop.
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Waste Electrical and Electronic Equipment Directive
The Waste Electrical and Electronic Equipment (WEEE) Directive requires the
recycling of waste electrical and electronic equipment. Whilst WEEE does not
apply to some of Raymarine’s products, we support its policy and ask you tobe
aware of how to dispose of this product.
The crossed out wheelie bin symbol, illustrated above, and found on our products signifies
that this product should not be disposed of in general waste or landfill.
Please contact your local dealer, national distributor or Raymarine Technical Services for
information on product disposal.
Warranty
To register your new Raymarine product, please visit the Raymarine website at the address
provided below. It is important that you complete the warranty registration to receive full
warranty benefits.
www.raymarine.com/warranty
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Introduction
Product description
Welcome to the installation guide for the Raymarine linear drive. This product is intended to
operate the boat’s steering mechanism as part of a Raymarine autopilot system. It is designed
for boats with existing mechanical steering systems.
The outstanding design of the Raymarine linear drive unit provides:
• powerful thrust, fast hardover times and quiet operation
• low backdrive force, to minimize the drive’s effect on the boat’s steering when the autopi-
lot is in standby
• a powerful electric motor controlled by an electromagnetic fail-safe clutch, using a high
tensile belt drive and epicyclic gearbox
• high performance for minimum current consumption
Figure 1: Main parts of the linear drive
CAUTION
Linear drive
This drive moves the rudder directly from the tiller arm or rudder quadrant.
Before installing the drive, check that the boat’s steering system can be back-
driven from the rudder..
D5075-1
Mounting foot
Push rod
Clutch cable Rod end
Motor, gearbox and
clutch assembly
Motor cables
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Contents
This guide contains:
Specifications
Drive specifications
1
Product specifications
page 7
2
Installation instructions
page 8
3
Maintenance information
page 17
Table 1-1: Drive specifications
Performance*
(at nominal voltage)
Type 1 (T1)
M81130 (12 V)
Type 2 short (T2S)
M81131 (12 V)
M81133 (24 V)
Type 2 long (T2L)
M81132 (12 V)
M81134 (24 V)
Maximum boat dis-
placement
10,000 kg
(22,000 lb)
15,000 kg
(33,000 lb)
20,000 kg
(44,000 lb)
Peak thrust 295 kg
(650 lb)
480 kg
(1,050 lb)
480 kg
(1,050 lb)
Maximum stroke 300 mm
(12 in)
300 mm
(12 in)
400 mm
(16 in)
Hardover to hardover
time
(+/- 35º, no load)
11 sec 11 sec 14 sec
Maximum rudder
torque
735 Nm
(6,500 lb.in)
1,190 Nm
(10,500 lb.in)
1,660 Nm
(14,700 lb.in)
Power consumption
(typical average)
18-36 W 48-72 W (12 V)
66-96W (24 V)
Other information (applies to Types 1 and 2 short/long)
protected for use in engine compartments
CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
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Drive dimensions
Figure 2: Linear drive dimensions
Installation instructions
Parts required
To install this drive you will need:
• Parts supplied:
• linear drive
• mounting foot assembly, consisting of: foot, pivot pin, washer (x2), R-clip (x2)
• tiller pin assembly (see
Figure 6
) consisting of: tiller pin, R-clip, top washer, lock
washer, nut (
1/2
inch UNC nylock)
• Additional parts:
• suitable securing bolts and lock nuts/lock washers (see
page 13
)
• suitable cable and electrical connectors for the drive motor and clutch (see
page 15
)
Note:
Make sure you have obtained these additional parts before you start installation.
90º
D5081-2
A (midstroke)
4 fixing holes suitable
for 10 mm (0.4 in) bolts
79 mm (3.1 in)
115 mm (4.5 in) 195 mm (7.7 in)
66 mm (2.6 in)
Drive Dimension 'A'
Type 1 700 mm (27.5 in)
Type 2 (short) 700 mm (27.5 in)
Type 2 (long) 850 mm (33.5 in)
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9
Installation steps
Follow these steps to install your linear drive unit:
Ð
Ð
Ð
1. EMC installation guidelines
All Raymarine equipment and accessories are designed to the best industry standards for use
in the recreational marine environment.
Their design and manufacture conforms to the appropriate Electromagnetic Compatibility
(EMC) standards, but correct installation is required to ensure that performance is not
compromised. Although every effort has been taken to ensure that they will perform under all
conditions, it is important to understand what factors could affect the operation of the
product.
The guidelines given here describe the conditions for optimum EMC performance, but it is
recognized that it may not be possible to meet all of these conditions in all situations. To
ensure the best possible conditions for EMC performance within the constraints imposed by
any location, always ensure the maximum separation possible between different items of
electrical equipment.
For optimum EMC performance, it is recommended that wherever possible:
• Raymarine equipment and cables connected to it are:
WARNING
Electrical safety
Make sure you have switched OFF the power supply before you start
installing this product.
1
Consult the EMC installation guidelines.
page 9
2
Mount the drive.
page 11
3
Connect to the course computer.
page 15
4
Complete the post-installation check.
page 16
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10
• At least 3 ft (1 m) from any equipment transmitting or cables carrying radio signals
e.g. VHF radios, cables and antennas. In the case of SSB radios, the distance should be
increased to 7 ft (2 m).
• More than 7 ft (2 m) from the path of a radar beam. A radar beam can normally be
assumed to spread 20 degrees above and below the radiating element.
• The equipment is supplied from a separate battery from that used for engine start. Volt-
age drops below 10 V, and starter motor transients, can cause the equipment to reset. This
will not damage the equipment, but may cause the loss of some information and may
change the operating mode.
• Raymarine specified cables are used. Cutting and rejoining these cables can compromise
EMC performance and must be avoided unless doing so is detailed in the installation
manual.
• If a suppression ferrite is attached to a cable, this ferrite should not be removed. If the fer-
rite needs to be removed during installation it must be reassembled in the same position.
Suppression ferrites
The following illustration shows typical cable suppression ferrites used with Raymarine
equipment. Always use the ferrites supplied by Raymarine. This product has ferrites mounted
internally.
Figure 3: Typical suppression ferrites
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment using a cable not
supplied by Raymarine, a suppression ferrite MUST always be attached to the cable near to
the Raymarine unit.
D3548-2
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11
2. Mounting the drive
Mounting the drive unit involves four main steps:
• ensuring correct drive alignment
• securing the drive to the boat
• connecting the drive to the steering system
• completing a steering check
Drive alignment
When mounting the linear drive unit, check that it is aligned correctly:
• The main drive assembly must be at right angles to the mounting surface (see
Figure 4
).
• The drive unit must be at right angles to the tiller arm when the rudder is amidships (see
Figure 4
).
Figure 4: Drive unit alignment
• The push rod must be accurately aligned with the tiller arm plane of rotation. The ball end
fitting only allows up to 5 degrees misalignment between the push rod and tiller arm
plane of rotation (see
Figure 5
).
CAUTION
Alignment
Accurate angular alignment is extremely important. You must not exceed this
+/- 5 degree limit under any circumstances.
A (mid stroke)
90º
D5077-1
90º
Drive A (mid stroke) B (tiller arm radius)
Type 1 700 mm (27.5 in) 250 mm (10 in)
Type 2 short 700 mm (27.5 in) 250 mm (10 in)
Type 2 long 850 mm (33.5 in) 355 mm (14 in)
B (tiller arm
radius)
Side view
Top view
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12
Figure 5: Alignment between push rod and tiller arm plane of rotation
Securing the drive
Mounting location
Before you secure the drive to your boat, you must first check the suitability of the mounting
location.
•Structural strength:
• This drive produces a considerable amount of force, so you must mount it on a solid
structure (i.e. a substantial frame member) in the boat. In some cases you may need to
build a special frame to mount the drive unit.
• To prevent excess noise and vibration, do not attach this drive to any structures that
support cabins.
•Drive orientation:
• You can attach the drive unit mounting foot to any suitable horizontal or vertical sur-
face. If required, you can also mount the drive unit upside down.
•General position:
• Refer to the EMC installation guidelines (
page 9
)
• Make sure the drive will be accessible for future servicing.
•Environment:
• This drive is not waterproof, so you should mount it in a dry location, clear of any bilge
water.
CAUTION
Mounting location
Consult the boat manufacturer if you have any doubt about the strength or
suitability of the mounting location.
D5078-1
5º Max.
5º Max.
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13
Securing bolts
Attach the mounting foot with four stainless steel M10 (
3/8
inch) bolts and lock nuts/lock
washers.
Note:
Always mount the drive as securely as possible to make sure it performs reliably and remains cor-
rectly aligned.
Connecting to the steering system
This drive produces a considerable amount of force, so you must ensure that your tiller arm or
rudder quadrant can cope with the peak thrust specified in the
Table 1-1, Drive specifications
.
Use one of these methods to attach the push rod to the rudder stock:
1. Independent tiller arm: we recommend that you attach the linear drive unit to the
rudder stock via an independent tiller arm (the Edson and Whitlock companies offer
standard fittings for their steering systems).
2. Steering linkage tiller arm or rudder quadrant: in certain cases, you may be able
to attach the push rod to the same tiller arm or rudder quadrant used by the main steering
linkage. Consult the steering manufacturer before you modify the rudder quadrant.
Attaching the rod end
Use the supplied tiller pin assembly to attach the rod end to the tiller arm, at the tiller arm
radius shown in
Figure 4
.
1. Attach the tiller pin to the tiller arm:
• insert the tiller pin through the tiller arm hole, so the flange remains above the arm
(see
Figure 6
)
• make sure that the tiller pin is a tight fit in the tiller arm
• use the supplied lock washer and fully tighten the lock nut
Note:
If necessary, you will need to drill a 13 mm (0.52 in) hole in the tiller arm at the radius shown in
Figure 4 .
2. Attach the rod end to the tiller pin:
• place the rod end onto the tiller pin
• secure with the supplied washer and R-clip (see
Figure 6
)
CAUTION
Equipment strength
Consult the steering gear manufacturer if you have any doubt about the
strength of the existing tiller arm or rudder quadrant.
81175_7.book Page 13 Monday, March 7, 2016 2:39 PM
14
Figure 6: Attaching the push rod to the tiller arm
Steering check
When you have mounted the drive unit, turn the boat’s steering wheel from hardover to
hardover and check that:
• Angular movement of the ball end fitting is less than 5 degrees (see
Figure 5
). If you
exceed this 5 degree limit, the drive will catch on the tiller arm/rudder quadrant and the
ball joint will bind.
• No part of the drive unit fouls the boat’s structure when the push rod moves in and out.
• The total rudder movement is limited to +/- 35 degrees by the steering system end stops
rather than the linear drive’s end limits (see
Figure 7
).
Figure 7: Total rudder movement
CAUTION
Linear drive
Make sure rudder movement is limited by the steering system end stops
before the push rod reaches its end stop. Failure to do this could damage
the drive and will invalidate the warranty.
Lock
washer
Tiller arm
Flange
Hole diameter
13 mm (0.52 in)
D5076-1
Tiller pin
Washer
Rod end
R-clip
Lock nut
35º35º
Steering system
end stop
Steering system
end stop
D5079-1
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15
3. Connecting to the course computer
The linear drive unit has electrical connections for:
• the drive motor: two single-core cables: red and black
• the clutch: a two-core cable with red (+) and blue (-) cores
Follow these steps to connect the linear drive to the course computer:
1. Measure the distance of cable run from the drive unit to the course computer:
•use
Table 1-1
to identify the appropriate motor cable size
• use at least 1.5 mm2 (16 AWG) copper cable for the clutch
2. Join these cables to the drive cables using appropriate electrical connectors or junction
boxes at the correct power rating.
3. Route the cables back to the course computer, taking into account the EMC installation
guidelines (see
page 9
).
4. Connect the cables to the course computer (see
Figure 8
):
•
CLUTCH
cable: red core to +ve, blue core to -ve
•
MOTOR
cables: at this stage you can connect either motor cable to either terminal.
You will check these connections after installing the rest of the autopilot system.
WARNING
Moving parts
Keep clear of moving steering systems at all times. Protect moving parts
from access during normal use.
WARNING
Electrical safety
Make sure the power supply is switched OFF before you make any
electrical connections.
81175_7.book Page 15 Monday, March 7, 2016 2:39 PM
16
Figure 8: Cable connections at SPX or ACU course computer
4. Post installation checklist
Check the following points after installing the drive:
1. Is the mounting foot secured to a substantial structure on the boat?
2. Is the drive unit correctly aligned, i.e:
• Is the mounting foot correctly oriented?
Table 1-1: Recommended cable sizes
Cable length
(drive unit to course computer)
Cable gauge
(AWG)
Copper area
(mm
2
)
Type 1 drive
up to 3m (10ft)
up to 5m (16ft)
up to 7m (23ft)
up to 10m (32ft)
up to 16m (52ft)
14
12
10
8
6
2.5
4
6
10
16
Type 2 drive 12 V (short/
long)
up to 5m (16ft)
up to 7m (23ft)
up to 16m (52ft)
10
8
6
6
10
16
Type 2 drive 24 V (short/
long)
up to 3m (10ft)
up to 5m (16ft)
up to 10m (32ft)
up to 16m (52ft)
12
10
8
6
4
6
10
16
GROUND
POWER
12V 24V
CLUTCH
MOTOR
AB
D13527-1
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17
• Is the drive mounted at right angles to the tiller arm, in a mid-stroke position, when
the rudder is amidships?
• Is the push rod accurately aligned with the tiller arm plane of rotation (less than 5
degrees variation)?
3. Is the linear drive rod end:
• securely attached to the tiller arm or quadrant?
• attached at the recommended tiller arm radius for the boat?
4. Are the motor and clutch cables correctly routed and securely connected to the course
computer?
5. Have you completed a hand-steering check (see
page 14
)?
Note:
When you have installed the entire autopilot system, you will need to complete an autopilot
steering check. Refer to the control unit handbook for more details.
Maintenance
Please make the following checks before each passage:
• Ensure that all connections and mountings are secure.
• Ensure that the drive is aligned correctly.
• Ensure that cables have no signs of wear or damage.
• Check for unusual noisy operation, such as clicking or grinding noises, or unusual vibra-
tion. If any of these are detected, the drive must be taken to a Raymarine authorized ser-
vice representative before further use.
• Ensure that the drive is not wet or exposed to water.
• Ensure that the swivel joint and rose-end are lightly greased with waterproof grease.
Note:
The drive should be serviced every 2 years or 1000 hours of use, whichever comes first, by a Ray-
marine authorized service representative.
EMC servicing and safety guidelines
• Raymarine equipment should be serviced only by authorized Raymarine service represen-
titives. They will ensure that service procedures and replacement parts used will not affect
performance. There are no user serviceable parts in any Raymarine product.
• Some products generate high voltages, so never handle the cables/connectors when
power is being supplied to the equipment.
• When powered up, all electrical equipment produces electromagnetic fields. These can
cause adjacent pieces of electrical equipment to interact with one another, with a conse-
quent adverse effect on operation. In order to minimize these effects and enable you to
get the best possible performance from your Raymarine equipment, guidelines are given
in the installation instructions, to enable you to ensure minimum interaction between dif-
ferent items of equipment, i.e. ensure optimum Electromagnetic Compatibility (EMC).
81175_7.book Page 17 Monday, March 7, 2016 2:39 PM
18
• Always report any EMC-related problem to your nearest Raymarine dealer. We use such
information to improve our quality standards.
• In some installations, it may not be possible to prevent the equipment from being affected
by external influences. In general this will not damage the equipment but it can lead to
spurious resetting action, or momentarily may result in faulty operation.
Product support
Raymarine products are supported by a worldwide network of distributors and Authorized
Service Representatives.
If you encounter any difficulties with this product, please contact either your national
distributor, or your service representative, or the Raymarine Technical Services Call
Center. Refer to the Raymarine website for contact details, FAQs, and also a dedicated forum
for customers to post and share product questions and knowledge: www.raymarine.com/
support
81175_7.book Page 18 Monday, March 7, 2016 2:39 PM
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