Wednesday, October 6, 2010

New AutoPilot system

It's been an uphill journey, but the new Raymarine AutoPilot system is nearly installed.
The Autumn Borne has a chain and cable steering system, but was fitted with a hydraulic linear ram, and pump system by Cetrek when we purchaced her.  Unfortunately, this system was flawed to begin with, as half of the helm display had been damaged by water intrusion.  So...as long as you "remembered" your keystrokes, you could use it to maintain a heading...  but after two years the rudder sensor broke, and the unit lost it's mind...(turning full to port, and popping the breaker).  No parts available any more... 

Anyway... we researched autopilots, and decided to go with the manufacturer we had on our Bayfield (Raymarine).  We ordered the X-30 corepack (very smart system !!), the ST6002 helm display (because it fits perfectly in the old Cetrek coaming opening), and the Type 2 hydraulic pump (with the intention of using it to power our existing hydraulic ram). 

We followed all the electronic checklists on the Raymarine site, and ordered what we thought were all the parts we'd need.  WRONG!!!  Until the pump actually showed up here at the marina, no one ever mentioned the required solenoid controlled bypass valve.   Intuitively, I sort of "knew" it had to be in the circuit, but IF no-one ever mentioned it... well maybe you could spin the pump backward when hand steering...  
The answer is  NOPE... without the bypass valve... the helm is LOCKED UP tight as a drum... when the air is bled out of the ram.

Installing the new gear required some planning to fit into the existing space, and not interfere with the movement of the ram, as the rudder quadrant moves.  I chose to reuse the two existing hydraulic hoses, from the ram to the new solenoid, because they're truly weird sizes (could be metric, but we could not duplicate them at Piping Plus (here in Catskill, NY).   We did purchase three new hoses (one extra) to go from the pump to solenoid controlled bypass valve.  We "lucked out" by having the correct number and sized wires already in place from the old Cetrek system... so all we had to do was 'extend' them to the new X-30 corepack location at the Nav Station (x-30 has to be installed vertically).

Fabricating two aluminum mounting plates allowed us to mount all the gear in accessible, and functional locations.  I'm now waiting for the Adapters (brass fittings) that Raymarine forgot to ship with the bypass valve.  [Both the Type 2 pump, and the by-pass valve are machined with British Standard Pipe (BSP) threads and are not compatible with the 'same size' National Pipe Threads (NPT)].  The last photo shows the system complete, with the container of hydraulic fluid for bleeding air from the ram, and pump.  The container is now gone, and the needle valve closed.  So far so good.  Now we need some sea-room for the seatrials, and associated calibration moves.   Yeah !!!

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