User manual RAYMARINE HYDRAULIC LINEAR

[. . . ] © Raymarine Ltd 2001. Hydraulic Linear Drive - Installation Guide 3 Introduction Welcome to the installation guide for the Raymarine hydraulic linear drive system. This product is intended to operate the boat's steering mechanism as part of a Raymarine autopilot system. The hydraulic linear drive system is designed for boats with existing mechanical steering systems, not hydraulic steering systems. It provides a totally isolated autopilot steering system consisting of: · Hydraulic ram: a self-contained autopilot steering cylinder with a load limiting system and a built in clutch (to allow friction-free steering when the autopilot is not in use). [. . . ] Mounting the drive components Mounting the drive components involves four main steps: · · · · ensuring correct hydraulic ram alignment securing the hydraulic ram to the boat connecting the hydraulic ram to the steering system installing the other parts of the drive system Ram alignment When mounting the hydraulic ram, check that it is aligned correctly: · · · The ram must be at right angles to the mounting surface (see Figure 4). The ram must be at right angles to the tiller arm when the rudder is amidships (see Figure 4). 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). 8 Hydraulic Linear Drive - Installation Guide A (mid stroke) View from astern 90º Drive Type 2 Type 3 View from above A (mid stroke) 540 mm (21. 25 in) 690 mm (27. 15 in) B (tiller arm radius) 180 mm (7. 1 in) 267 mm (10. 5 in) 90º aft B (tiller arm radius) D5091-1 Figure 4: Hydraulic ram alignment 5º Max. 5º Max. View from astern D5092-1 Figure 5: Alignment between push rod and tiller arm plane of rotation CAUTION: Accurate angular alignment is extremely important. You must not exceed this +/- 5 degree limit under any circumstances. Securing the hydraulic ram Mounting location Before you secure the hydraulic ram to your boat, you must first check the suitability of the mounting location. CAUTION: Consult the boat manufacturer if you have any doubt about the strength or suitability of the mounting location. Hydraulic Linear Drive - Installation Guide 9 · · · · Structural strength: · This drive produces a considerable amount of force, so you must mount it on a solid structure (i. e. In some cases it may be necessary to build a specially strengthened 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 must mount the hydraulic ram horizontally with its mounting foot on a horizontal surface (see Figure 6). The swivel joint does not have sufficient movement to position the mounting foot vertically. General position: · Refer to the EMC installation guidelines (page 6) · 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. View from above aft View from above aft D5089-1 Figure 6: Drive orientation Securing bolts Attach the mounting foot with four stainless steel M8 (5/16 inch) bolts and lock nuts/lock washers. Note: Always mount the hydraulic ram as securely as possible to make sure it performs reliably and remains correctly aligned. 10 Hydraulic Linear Drive - Installation Guide Connecting to the steering system CAUTION: Consult the steering gear manufacturer if you have any doubt about the strength of the existing tiller arm or rudder quadrant. 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, Ram 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 push rod to the rudder stock via an independent tiller arm (Edson and Whitlock offer a standard fitting). 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. 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 7) · 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 hole in the tiller arm at the radius shown in Figure 4. R-clip Washer Rod end Flange Tiller arm Lock washer Lock nut Tiller pin Drive Type 2 Type 3 Hole diameter 'X' 13 mm (0. 52 in) 20 mm (0. 78 in) X D5090-1 Figure 7: Attaching the push rod to the tiller arm Hydraulic Linear Drive - Installation Guide 11 2. Even the smallest particle of dirt could prevent the steering system check valves from working properly. Connecting to the course computer WARNING: Electrical safety Make sure the power supply is switched off before you make any electrical connections. The hydraulic linear drive system has electrical connections for: · · the motor in the pump: two cables: red (+) and black (-) the clutch in the hydraulic ram: a two-core cable with brown (+) and blue (-) cores Hydraulic Linear Drive - Installation Guide Table 2: Recommended cable sizes Cable length (pump to course computer) Type 2 drive 12 V up to 5 m (16 ft) up to 7 m (23 ft) up to 16 m (52 ft) Type 2 drive 24 V up to 3 m (10 ft) up to 5 m (16 ft) up to 10 m (32 ft) up to 16 m (52 ft) Type 3 drive 12 V up to 5 m (16 ft) up to 7 m (23 ft) up to 16 m (52 ft) Type 3 drive 24 V up to 5 m (16 ft) up to 7 m (23 ft) up to 16 m (52 ft) Cable gauge (AWG) 10 8 6 12 10 8 6 8 6 4 10 8 6 Copper area (mm2) 6 10 16 4 6 10 16 10 16 25 6 10 16 13 Connect the pump and ram to the course computer: 1. Measure the distance of cable run from the pump and ram to the course computer: · use Table 2 to identify the appropriate motor cable sizes · use at least 1. 5 mm2 (16 AWG) copper cable for the clutch 2. [. . . ] Some products generate high voltages, so never handle the cables or 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 consequent 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 different items of equipment, i. e. [. . . ]