BT-82

Autopilot

Instruction Manual

BETTER MARINE ELECTRIC WORKS

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 JIAOJIANG TAIZHOU CHINA
Address: 180-2 Yang Guang Road, Jiaojiang district,
Taizhou city, Zhejiang, Province, China
Post code 318000 Tel 0576 - 88897978
Version: 0704.1 E-mail xzc@mail. tzptt. zj. cn Fax 0576 - 88881109

Contents

Foreword...................................................................................................................... 2
I. General...................................................................................................... 3
II. Construction of BT-82 Autopilot................................................................... 5
1. Master Steering Stand................................................................................... 6
2. Magnetic course Sensor............................................................................ 13
3. Rudder Angle feedback................................................................................ 13
4. Steering box in Steering gear Room......................................................... 13
5. Starter for Steering Gear............................................................................ 13
6. Auxiliary station (optional)......................................................................... 14
III. Technical specification............................................................................ 15
IV. Operational procedure............................................................................ 16
V. Installation instruction................................................................................ 25
VI. Alignment & Testing................................................................................ 26
VII. Trouble shooting...................................................................................... 34
VIII. Maintenance............................................................................................ 40
IX. Spare Parts............................................................................................ 41
X. Warranty................................................................................................... 41
Appendix................................................................................................................... 42
1. BT-82 Autopilot - Outline & Mounting...................................................... 42
2. CS-32 Magnetic Course Sensor............................................................ 43
3. FB-82 Rudder Feedback - Outline......................................................... 43
4. Steering Box - Outline & Dimension......................................................... 44
5. Starter - Outline & Dimension................................................................... 44
6. Wiring Diagram - Steering Stand............................................................ 45

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7. Wiring Diagram SGC Steering Box...................................................... 46
8. Wiring Diagram Port Starter................................................................... 47
9. Wiring Diagram Starboard Starter......................................................... 48
10. System Wiring Diagram......................................................................... 49

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 Foreword

This instruction describes how to install, operate, maintain and inspect the
autopilot. Please read the instruction carefully before the operation. In addition,
always keep the instruction in your pilot house so that you can consult the instruction
any tine, it is very important for safe & smooth operation of the equipment.

Though the instruction try to make out all kinds of safety related matters in the
process of installation, operation, maintenance, however, it is impossible to predict
all hidden troubles, in case of special situations, please take appropriate measures
to avoid accident occurrence.

IMPORTANT NOTES TO SAFE OPERATION!

Do not use automatic steering when in heavy traffic areas or in narrow

waters, in poor visibility or rough sea conditions, such as fog, storm, because
it could cause a serious accident.

Trust the equipment, but do not just rely on it. Do not leave the operating
position, do not take a nap during the on.

Automatic steering works on the course signal from Gyrocompass or

magnetic compass's sensor, therefore it depends on the precision of course
detected. When magnetic compass course is the course benchmark, if
magnetic compass interfered by outside magnetic field, there will be distinct
error of the course provided. the vessel may deviate from the setting course
obviously. When in mode of navigation, it is controlled by the heading
information from GPS satellite navigation system. it will depend on the
precision of GPS signal. In consideration of the influence of wind, flow, wave,
if we just rely on automatic steering, it may result in collision and stranding.
To avoid the happening of these marine perils, keep a close eye on sea
state, never neglect to check the course and keep watch.

When vessel turns according to the setting rate of turn, vessel's rate of turn is
restricted by maximum steering angle limit of automatic mode, if the allowed
maximum ruder angle is too small, the vessel's rate of turn will not reach the
setting rate of turn.

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I. General

There are a lot of benefits for vessels to equip with autopilot: lower fuel
consummation, lower labor intensity and longer service life etc. Usually, automatic
steering is accomplished by the course signals provided by Gyrocompass, so
vessels of middle and small size without Gyrocompass can not realize automatic
steering.

BT-82 autopilot is a newly designed type of automatic pilot based on the

experiences worked at in the past many years. Moreover, it meets the technical
requirements of Rules for Building and Classing Steel Vessels (version 2006) of
CCS.

Both gyrocompass and magnetic compass can provide course signals to BT-82
autopilot. When Gyrocompass can not start or it is in the setting period after starting,
automatic steering could perform by magnetic course signal from magnetic compass.

BT-82 autopilot can receive serial signals from GPS or ECDS in APB sentence
format (which accords with NEMA0183 or IEC621162-1 requirements) to realize
automatic steering.

BT-82 autopilot adopts variable gain PID rudder control, and with wide range of
parameter adjustment, so it performs well under different weather on different
vessels.

BT-82 autopilot applies solid electric circuit in its inner part, so it has a reliable
performance, compact construction, and is easy to operate and maintain. It is
suitable to all size of vessels, such as: passenger vessels, cargo, tanker, fishing
boat, working vessel, patrol craft, traffic boat and so on. And it has the following
characteristics,

Stable heading
It adopts variable gain PID ruder controller, therefore, both rudder angle and
vessels heading are always under the control, so that quite stable heading will
be maintained.

Control of maximum rudder angle & maximum rate of turn in

automatic steering
It can control and restrict the maximum rudder angle as well as the maximum
rate of turn, avoiding vessel's overturning, ensure the safety of the vessel.

Automatic WEATHER(sensitivity) adjustment in automatic steering

WEATHER (sensitivity) can be adjusted automatically, that the allowed vessel
yaw value is changed automatically according to sea condition. The value is
increased in heavy sea to minimize rudder movement and reduce propelling
power loss, and decreased in calm sea to improve heading's stability.

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 Distinctive anti-overshoot adjustment
It has the function of adjustable anti-overshoot, which could eliminate oscillation
of hydraulic system effectively.

Multi-Interfaces
It can connect flexible with relevant equipment via analog interfaces and
digital serial ports, e.g., Gyrocompass, magnetic compass, satellite
navigator, ECDIS, VDR, and so on.

Various alarm devices

It can generate alarms regarding electric power loss, open phase,
overload, low liquid level, filter block, high temperature of hydraulic oil,
block of hydraulic system, off-course, compass error, loss of 24V DC
power, power loss of steering stand. In addition, it also has functions of
alarm test and mute.

Alternative power supply

The control circuit ensures the two pumps are backed up each other, that
is, if malfunction occurred in one power supply or one pump, the other
one pump will immediately start work automatically to ensure the normal
operation of the system.

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 II. Construction of BT-82 Autopilot

BT-82 automatic pilot consists of master steering stand and other peripheral
equipment. The table below shows the basic equipment with options.
Supporting equipment is necessary for the execution of automatic steering in NAVI
control mode and PILOT control mode accordingly.
Type
Small-size Middle &
BT-82 Steering control system
vessel large
vessel
MSS 82 BT-82 Steering Controller 1 1
Master
Master Steering 38-V Course Repeater 1 1
equipment
Stand
ST Starter 2 2
Peripheral
SGC steering box 1 1
equipment
FB 82 Rudder Feedback 1 1
Grade A Magnetic Compass requisite requisite
CS-32 Magnetic Course Sensor requisite Optional
Option or Gyrocompass requisite
provided
AD-32 Analogue/digital Converter for Optional
equipment by
customer Gyrocompass
GPS Satellite Navigator Optional
Chart Plotter Optional

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Page 7 of 49
1. Master Steering Stand
Master steering stand is the
centre of the equipment. It executes
function of receiving, calculating,
amplifying, transmitting, indicating
and order-issuing of steering control
signals.
The controller and operational
unit of master steering stand is on
the control panel, which is on the top
of the stand and is inclined with an
angle of 35relative to horizontal
level, for details, see Fig 1, from top
to bottom, and from left to right, they
are course repeater and its match
knob, steering controller, dimmer,
non follow-up steering switch, power
and pump system select switch,
wheel for hand steering and steering
mode select switch. 1Power/pump selection switch
2Hand steering wheel
1.1 Course repeater 3Steering mode selection switch
4NFU (Non-follow-up) steering Handle
It is to indicate the actual heading 5Master steering controller
of the vessel. This value may come 6Course repeater
from gyro compass or magnetic
compass. Course repeater can receive Fig 1- Layout of Master Steering Stand
HDT data in the format of standard
NEMA0183 & IEC6 162-1 via interface
RS 232, and repeat the present heading at steering stand with two modes of
"analogue" and "digital".
Two buttons near the right bottom are dimmers and course match button, there
are two functions,

First function: illumination adjustment

It is a frequently used function, press the right button, the brightness on` the repeater
will be increased, and press the left button, the brightness is reduced.

Second function: synchronization match up of course indication

In case that two indications are out-of-step, that is, dial indication is not consistent
with digital indicationpress the both buttons simultaneously to resume the
synchronization between two indications.

If the course is analogue signal, which cannot transmit by serial port, the synchro
signal or step signal (6 step/degree), it must conversed into HDT format signal via
"AD-32 analogue/digital converter for compass " (optional), and transmit to course
repeater.
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1.2 Steering controller
Steering controller is in the center of the control panel, is the core equipment to
perform all functions.
The operational panel of the steering controller is divided into four sections:
Sction 1 - automatic steering parameter adjustment
Sction 2 - Digital display for Heading/Rate of Turn & Setting Course/ Setting
Rate of Turn.
Sction 3 - operating stats indicator and steering mode select
Sction 4 - alarm indicator

Fig. 2: Layout of control panel

A.
Automatic steering parameter adjustment
There are four knobs and a pair of rudder movement indicators.

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There are four knobs:
WEATHER (Sensitivity) adjustment
To set the minimum deviation angle allowed. If yaw angle is bigger than the
value, autopilot will send out rudder order immediately. There are two ways
for setting:
Automatic setting counter clockwise turn the knob to the end.
Manual setting turn the knob to the expected allowed yaw angle.
RUDDER adjustment
To set rudder movement in one degree step from heading deviation angle,
that is, the ratio between rudder movement and heading deviation angle. If
the setting is too large, that the vessel may yaw, and if the setting is too little,
that the vessel could not return to the setting course quickly. The range is 0.
8 2. 5, usually, it's about 1. 2.
RATE adjustment
That is differential adjustment, to adjust the dynamic stability of the vessel.
Appropriate adjustment could improve the headings stability on a straight
course, enable the autopilot automatically change into new course quickly
and smoothly without over-shoot or sluggish response.
LIMIT adjustment
The value determines the maximum rudder movement allowed in degrees, it
is very important for tankers etc, for which turning with large rudder angle is
not allowed in order to avoid vessel's overturning. The range is 5 to 35,
and it is only effective in automatic mode.
Below the four knobs, there are two indication lamps: "PORT" and "STBD". If
the left triangle lamp is lit, indicating the port rudder is in use, while the right triangle
one is lit indicating the starboard rudder
is in use.
Two strip indication lamps outside
the triangle indicators are for rudder
limit . When the left lamp is lit, it means
that port rudder reach the rudder limit,
the right lamp is for starboard rudder limit
indicator.

B.
Digital display of Heading/ROT &
setter for Setting Course/ROT
There are "Heading/ROT (Rate of
Turn )" indicator, "Setting Course/ Turn
Rate " indicator, "COURSE/ROT set"
setter, and "CRS set", "ROT set" select
button (see right figure).

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 Heading/ROT" indication is a four digit display, to indicate present heading
(resolution: 0.1 degree) provided by gyrocompass or magnetic compass according to
the selected signal source, or to indicate present turn of rate (resolution: 0.1per
min.). Detailed information refers to the next section.
"Setting course/ROT" indication is a three digit display to indicate the setting
course, which is set by officer, with a resolution of 1 or setting rate of turn by 1 per
minute.
Whether the two displays indicate the heading or rate of turn, it is selected by the
knobs in the right-hand corner and LED lamps on the right side will be lit accordingly.
Press the "CRS set" button, "Head." and "Course" indicators will light up at the same
time, two displays indicate the present heading and present setting course
respectively. If press the "ROT set" button, the two "ROT" indicators will light up at
the same time, two displays indicate vessel's present rate of turn and the setting rate
of turn set by officer.
"COURSE/ROT SETTING" setter is a pulse coder, to set the vessel's setting
course (order course) or setting rate of turn. In automatic steering, autopilot will
control the vessel's heading automatically to keep the vessel on the setting course,
or turn the vessel with this rate of turn as maximum rate if it is allowed for vessel.
To change the setting course, press the "CRS set" button, then two displays
indicate present heading and setting course respectively, and reading on "Setting
Course/Turn Rate" display will flash, then turn COURSE/ROT Setting knob to
change the setting course reading. To put the new setting into effect, press CRS
set button again, new setting course is confirmed at this moment and Setting
Course display stops flashing. Otherwise, new setting is ineffective without
confirmation, Setting Course display will resume the previous reading and stop
flashing 3 seconds later.
To change vessels maximum rate of
turn, press the ROT set button, after set
setting ROT, it must re-press the ROT set
button for confirmation of the new setting,
the method is the same as the above.
Clockwise turn the COURSE/ROT
SETTING setter, the setting value
increases, otherwise, the setting value will
decrease if counter clockwise turning. Turn
the setter a circle, 24 impulses is sent out,
course setting change 24 or rate of turn
setting change 24per minute.

C.
Operational status indicator & mode
selection in automatic steering
mode
There are operational position indication lamps, steering mode indication
lamps, steering course signal selection, and dimmer knob.
There are two lamps show operational position, it means that the steering
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control is in bridge if the upper green one (CTRL IN BRIDEGE) is lit up, while the red
one (CTRL IN STERN) means it is controlled in Steering gears room.
There are four green indication lamps of operation mode to show the steering
mode, AUTO (automatic steering mode), HAND (hand steering mode), NFU (Non-
follow-up steering mode), AUX (auxiliary station steering mode) respectively, the lit
one means the effective steering mode.
In automatic steering mode, there are two modes: PILOT control mode and
NAVI control mode.
PILOT Control Mode: it keeps the vessel on the planned course by
automatically sending rudder order according to course provided by compass as the
planned course set by officer.
NAVI (navigational) Control Mode: officer set the planned course on satellite
navigational devices or chart plotter, satellite navigational devices send out new
course order accordingly, autopilot receives this course order and perform steering
automatically, keep the vessel on the planned course.
When changing to automatic mode from other steering mode, default
setting is "PILOT" control mode with vessel's present heading as planned
course.
Press "PILOT" button or "NAVI" button to select automatic steering mode.
There is a green indication lamp on PILOT button. During automatic steering
mode, if press PILOT button, the lamp will light up, it means that setting course by
course setter is the planned course of automatic steering.
There are two indication lamps on NAVI button, once the autopilot receive the
signal from satellite navigator or chart plotter, the right yellow indication lamp lights
up, it means that this mode is available. If the signal from satellite navigator or chart
plotter can not be received, the yellow indicator will not light up, the mode is
unavailable.
During automatic steering mode, press NAVI button, till the left green
indication lamp is lit up, it means that course signal from satellite navigator or chart
plotter is the setting course of automatic steering.
There are two buttons for course signal source selection: MAGN (magnetic
compass) and GYRO (Gyrocompass). There is one yellow indication lamp and one
green indication lamp on each button respectively, yellow indicator means that this
course signal is available for steering controller in automatic mode. If the autopilot
receives from both course signal sources at the same time, the default setting is
magnetic compass when start-up, its green indicator lights up, course of magnetic
compass shows on the heading display. To select Gyrocompass as course signal
source, press the GYRO button till its green indication lamp is lit up while the green
indicator on MAGN (magnetic compass) is went out, it means that Gyrocompass is
the course signal source in automatic mode, at the same time, present heading of
Gyrocompass is shown on the course display. If you want to change the course
signal course back to magnetic compass, same method to press MAGN button to
return the course signal source to magnetic compass.
Caution: to ensure the safety, do not change course signal source

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 in automatic steering mode. If changing the course signal source in
automatic mode, vessel may turn suddenly due to the difference
between two course signals.
Two buttons at the bottom are dimmers for illumination adjustment, press the
right button to increase the brightness of indication lamps, while press the left one to
decrease the brightness.

D.
Alarm indication

There are three groups, totally 20 pieces alarm indication lamps. The upper
two groups monitor the operation of port & starboard power supply and pumps, total
is 8 items in each group.
The indication lamps at the left top corner of each the groups display indicate
the operation status of left and right pumps respectively, the lit one means the pump
is running. Each group has 8 red indication lamps to monitor the port and starboard
power as well as hydraulic system. The text marked denote following meaning:
CTRL PWR selected main power (380V) in
bridge is lost
STICK failure of hydraulic system results
malfunction in steering system.
POWER power for hydraulic system is lost
LEVEL level of hydraulic tank is too low
LOAD engine of hydraulic system is over-
loaded
PRESS. Oil filter of hydraulic system is
blocked
PHASE Any one phase of hydraulic system
power is lost
TEMP. Temperature of hydraulic oil is
higher than setting
The third group has three red indication
lamps and a pair of two-color indication
lamps to show the status of compass, off
course, power system and battery.

COMPASS course difference between Gyrocompass and magnetic compass is

greater than 10.
COURSE difference between present heading & setting course is greater than 10.
SYSTEM FAIL inner circuit failure of master control unit, automatic mode and hand
mode is out of order.
DC 24V the red alarm lamp will light up if vessels 24V DC power is lost or the
voltage is insufficient (less than 18V), if the 24V DC power is supplied
normally, the green lamp will light up.
There are TEST and MUTE button at the bottom.
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 The left button with symbol of "TEST" is to test alarm system, press the button,
all alarm indication lamps will light up with audible alarm, to check the alarm system
is whether in good condition, pressing the right button (MUTE) to respond the alarm.
In case of alarm occurrence, the indication lamp will flash with audible alarm
sound of du du. Press MUTE button to silence the alarm, and the lamp changes
from flashing to steady lighting, and it is went off automatically if the trouble is
cleared. In addition, Mute the former alarm do not affect the function of re-alarming
with audible sound for another alarm.

1.3 NFU Steering Handle lever

NFU steering handle is in the right side the control panel, it is a self- reposition
switch to perform NFU steering. NFU switch has a character of "OVERRIDE"
wherever the steering mode select switch is on, so long as NFU is in operation,
rudder will execute its order at once, other orders become invalid. However, as soon
as NFU steering switch return to the center position, it is so steered again as the
mode indicating on steering mode select switch.

1.4 Power & hydraulic system Select switch

Power & hydraulic system Select switch is in the bottom left-hand corner of the
control panel.
Counter clockwise turn "POWER" knob, port hydraulic system is put through
and started. Clockwise turn the power knob, starboard hydraulic system is put
through and started.
Between port & starboard main power supplies, and between port and
starboard hydraulic system they are backed up each other, that is, if one main power
is lost, the other one will be supplied automatically while the alarm is sending out. If
the selected hydraulic system can not be started, the other one will supplied to
steering stand while the alarm is sending out. If selected power resumes normal, the
original selected power and hydraulic system will resume running automatically, and
alternative power and hydraulic system will quit automatically.
As the power supplies are backed up each other, the two hydraulic pumps
might start up at the same time for a short while if initial starting. This is a normal
phenomena, the hydraulic system which is not selected will stop soon after.

1.5 Hand steering wheel

Its at the bottom center of steering stand. It includes a set of wheel geared
with rudder order Sensor, hand rudder order/angle indicator.
Hand rudder order/rudder indicator is in the rear of wheel, it has two indexes,
one indicates hand rudder order sending by wheel and one indicates rudder's
present position.

1.6 Steering mode select switch

There are four selections with following meanings,

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 Automatic in this mode, it is steered automatically, there are two choices:
PILOT control mode and NAVI control mode, details refer to the relevant contents on
page 10.
Hand in this mode, operator operates steering wheel sending out rudder
movement order, rudder follow up the order and arrive at destination position
automatically.
NFU (Non-Follow-Up) in this mode, operator operate NFU steering handle to
move or stop the rudder.
Auxiliary station it is steered by optional steering controller. Usually, it refers
to the simple steering devices mounted at the both wings of bridge.

2. Magnetic course Sensor

Its to detect magnetic course. Usually, its in the top center of compass bowl of
magnetic compass, as its very small, it do not affect looking readings on the card of
magnetic compass.

3. Rudder Angle feedback

Rudder feedback is used to detect the actual position of rudder.
Connecting rods, rocker arm of rudder feedback and helm bar construct a
parallelogram to actualize transmission synchronization. The length of rocker arm is
adjustable, so it is easy for installation & adjustment.
Synchro is adopted to detect the rudder position in rudder feedback.

4. Steering box in Steering gear Room

Steering box is mounted in the Steering gears room, and there are port pump
indication lamp, right-pump indication lamp, "control in bridge" indicator, "control in
stern" indicator, operational position select switch, NFU steering switch in the
steering box.
Operational position select switch is used to change the operation place.
When its on the control in bridge position, then rudder order is sent out from
steering stand, and operation in Steering gears room is invalid. When it's on control
in stern position, operation in bridge is ineffective, and it is steered only by operating
NFU steering switch of steering box in Steering gears room.
Steering box is powered by two 380V AC from port and starboard pump starter
respectively. There are two sets of power conversion circuits to transform the power
from 380V AC into 24V DC and supply to solenoids of port and starboard hydraulic
systems respectively.

5. Starter for Steering Gear

Steering gears of different power should allocate with different power starter box,
which should be specified in order.
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 There are two starters to control the start-up and turn-off of the port and
starboard hydraulic system respectively.
Port and starboard starters are supplied by three-phase power from main
distribution board, emergency switchboard along with port and starboard
respectively, and there are backed up each other, if one three phase main power is
lost, then power supply is switched to the other one automatically. When connecting
with starter, make sure that they are on the same phase, and otherwise, it may result
in short circuit and switch off.
Each starter has one three-position switch, three positions are remote control
(control in bridge), turn-off, starting, if all they are on "remote" the position, operator
could start up or turn off any one hydraulic system in bridge. If the switch of one
starter is on the position of "starting" or "stop", then the according hydraulic system
can be started and turned off in Steering gears room, therefore, steering can be
performed by operating steering box in Steering gears room. (For details, see the
last section of steering box).
When starting and turn off the hydraulic system in bridge, all above-mentioned
switches should be on "bridge" position. At this time, if both main power supplies can
not start the selected hydraulic pump, another pump will be started automatically to
ensure the normal operation.
In addition, there are monitoring functions for hydraulic system with detecting
and transmitting alarm signals of the system. In case of malfunction of hydraulic
system, it will send out visual and audible alarm at once. There are six monitoring
items: loss of power for control system, phase loss of power system, overload of oil
pump, over-high pressure of oil filter, over-low liquid level in oil tank, over-high oil
temperature. In addition, there are test knob to test alarm system and mute knob
to silence the alarm. Mute the former alarm do not affect function of another
alarming with audible sound again.

6. Auxiliary station (optional)

Generally, it means the steering devices on both wings of bridge. A simple
steering box is the simplest auxiliary station. When mode select switch is on "AUX."
position, and Aux. indication lamp lights up, it means that steering in bridge wings
is available, and steering is controlled by directly operating the switch on any one
auxiliary station. However, the two auxiliary stations are interlocked each other, that
is, if operation in two auxiliary stations simultaneously, both controls are invalid.

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III. Technical specification

Working temperature: -10 +55

Power supply:
Main power 380/44V ~50/60Hz 250 VA
Emergency power 24VDC 150W (back-up)
Heading Repeat Type: Analog display: dial: 0 360, 1per
graduation
Digital display: 4-digit, Min. display: 0. 1

Course transmission error Not more than 0.5

Steering mode: Automatic, Hand, Non-follow-up
Automatic steering:
Rudder order error Not more than 0. 5
Course error of automatic steering Mean value: no more than 1 ,
Maximum value less than 1. 5 (calm sea)
Hand steering:
Follow-up sensitivity Not lower then 1
Follow up error Not more than 1
Rudder indicator range: 35, 1per graduation
Rudder indication error Not more than 1
Output controlling elements: solenoids (24V 2 A

Digital interface: RS 232 RS422

---- sentence format in accordance with regulation MNEA0183

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IV. Operational Procedure

1. Start-up & turn off

Start-up
Preparation: close the switch on the main switchboard and emergency
switchboard to provide power supply to hydraulic system of pilot.
Put the steering mode select switch to "NFU" position.
Put the "Power/Pump" select switch to the selected power/pump system. Then
the port or starboard hydraulic system is put through and started up, then the
steering gear put into normal operation at once. After that, put the 24VDC switch on
sub-distribution box to "ON" position as well.
Before vessels sailing, check the port rudder system and starboard rudder
system in every operational mode one by one, be sure that both systems and all
modes are in good condition.
At last, put the steering mode on "Hand" position, rudder on amidship, waiting
for sailing.

Turn off
Preparation: turn to NFU steering mode, and set the rudder on amidship.
Put the "POWER/PUMP" knob on "OFF" position, the autopilot and hydraulic
system will stop operation immediately. Then, put the switch of 24V DC on sub-
distribution box to "OFF" position, and switch off the main switchboard, power for
autopilot is cut off.

Course Match after starting

After starting, the course repeater will match the course automatically, follow
and indicate the course of gyrocompass or magnetic compass that depends on the
pre-setting and can be changed after start-up, and with a 4-digit LED display.
If the input of gyrocompass is analog signal (from synchro or step-by-step
signal), make sure the course signal of AD-32 analogue/digital converter match up
with the output of Gyrocompass first.
"Heading" & "Setting Course" display (4-digit LED light) on control panel shows
the compass course too, default setting is the course of magnetic compass, and
green indication lamp on "MAGN" button is lit.
To change the course benchmark to gyrocompass, press the "GYRO" button,
along with a whistle of buzzer, green indicator on "GYRO" button is lit while the
indicator on "MAGN" is went out. Heading display shows the course of
Gyrocompass.

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2. NFU(Non-follow-up )steering
NFU steering in bridge
NFU steering mode is a kind of emergency backup mode that is seldom used.
But it is necessary to check it frequently to make sure its normal operation in case of
emergency.
So long as the operation is in bridge, NFU steering mode can be used at any
time no matter what mode it is in, because it has a character of OVERRIDE.

a. Turn "NFU handle to port or starboard, rudder will move to the

selected direction. Rudder stops till releasing the handle, and the handle
will turn back to original position automatically. Otherwise, it may be hard
helm.
b. Release the handle when rudder reaches expectation position, and
handle turn back to center position automatically then rudder stops. For
some systems, rudder may continue moving for some distance after the
handles releasing & returning, it is so called overshoot, so release the
handle in advance or turns it oppositely according to actual situation,
make the rudder paddle on the expected position.
c. Although "NFU" handle can be used no matter what mode it is in, it will
resume to the selected mode as soon as handles releasing and
returning. In the case if you want in NFU" steering, must turn mode
select switch to NFU position.

Steering in auxiliary station located the wings of bridge optional

If there are simple steering boxes on both wings of bridge, NFU steering can
be performed in both wings of bridge. Carry out
Put the steering mode select switch is on AUX. position, and indication lamps
on simple steering boxes will light up at the time, it means that steering in two simple
steering boxes is available. When operating on one steering box, its indication lamp
on, then the lamp in the other box will automatically go off and retreat from control
since the two are interlocked each other.
If operating at both sides simultaneously, then both controls are invalid, pay
attention to avoid the situation.

Steering in Steering gears room

Whether bridge steering stand is in operation or not, steering can be performed
in Steering gears room according to the following procedures.
Start up one set of hydraulic system, turn the position select switch to "control
in stern" position, then steering is performed by steering switch on steering box.
If steering stand is in operation and "control in stern" indication lamp lights up,
operation in bridge is ineffective. When the position select switch turns back to
"Control in bridge", rudder is under control of steering stand in bridge, while
operation in Steering gears room is ineffective.
Page 19 of 49
 When operation in Steering gears room, the hydraulic system can be started
from bridge as well as Steering gears room by manual, so long as put the select
switch on starter on "ON" or "OFF" position, the hydraulic system will be started or
turned off.
When turn back to control in bridge, all the position select switch of the starter
and steering box located in Steering gears room should be at the "bridge or remote
control" position, to ensure the complete control of steering system in bridge.

3. Hand steering
Hand steering is a steering mode used commonly, especially when entering and
leaving harbor or sailing in narrow water.
To perform hand steering according to the following procedures:
a. Turn the steering wheel, and make the pointer of rudder indicator point at
present rudder angle.
b. Turn the mode select switch to hand steering position, the "hand" indication
lamp is lit then the system is operated in hand steering mode.
c. Turn the wheel to port or right sending out the order moving to port or
starboard, the value is determined by the turning angle of the wheel, which is
indicating by the pointer of rudder indicator. The rudder will automatically
follow and reach the order.
4. Automatic steering
Automatic steering is a mode used often during the long voyage, to ensure the
safety, watch the sea carefully, and

Caution: Do not use automatic steering mode in narrow water

and when entering and leaving harbour.

To realize automatic steering according to the following procedures:

a. Make sure that all parameter adjustments of automatic steering are on

normal positions:

WEATHER - at "W.A." position, or 0.5 or 1 in calm sea

-
RUDDER - usually it's about 1.2, or 1.5 when heavy-load
-
RATE - it is determined by vessels load: 1 for light loaded, 4 for
- half load and 6 for fully load.
LIMIT - it is determined by vessels type and operators'
- experiences. Usually, 10 for container, 15 for bulk
cargo and tanker.

b. Operate and make vessels actual course agree with expectation course.
Confirm that the selected course benchmark for automatic steering is
effective, both the green and yellow indication lamps are lit.
c. Turn the mode select switch to AUTO position, and AUTO indication lamp

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 is lit. Then, it keeps vessel on the present course of the moment, the heading
at that time will be the setting course automatically.

Control mode of automatic steering

PILOT control mode is the default setting after changeover to automatic

steering, at this time, green indication lamp on PILOT is lit, while green indication
lamp on NAVI is turned off.

Mode changeover in automatic steering

Form PILOT control mode to NAVI control mode

Attention: satellite navigational signal input is necessary for NAVI control
mode, that is, NAVI is only available till its yellow indication lamp lights up.
Press the NAVI button, with a whistle of the buzzer, till the green indication
lamp on NAVI button lights up while green lamp on PILOT button is turned off.
Course signal from satellite navigator is the setting course of automatic
steering. It is based on the setting course set by officer on satellite navigational
devices in advance.
Remarks:
1. Waypoints should be set on satellite navigational devices before
performing "NAVI" control mode in automatic steering.
2. In NAVI mode, COURSE/ROT SETTING setter on steering
controller can not be set by manual.
3. When there is input from GPS waypoints information, red indication
lamp on NAVI button will flash, if the new setting course can not
be received, autopilot will keep straight course on the setting
course received in the last time.

From NAVI control mode to PILOT control mode

Press PILOT button, with a whistle of buzzer, till the green indication lamp on
PILOT button lights up, while green indicator on NAVI is went out. The present
heading of the moment will be the setting course for automatic steering.

WEATHER Changeover in automatic steering

From automatic adjustment to manual setting

Turn the knob, and set the index on the designed value.

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 From manual setting to automatic adjustment
Counter clockwise turn the knob to the end (W.A. position), and automatic
adjustment indicator is lit, showing the weather adjustment is changed into automatic
adjustment. As its previously set by manual, at this time, the value supplied by
automatic weather adjustment may not be the best. If the previous manual setting is
too low, the rudder may move frequently during the time, resulting in a larger
automatic setting and vessel allows a larger deviation range in initial stage. If
previous manual setting is too large, the automatic setting is relative low, resulting
frequent movement of rudder in initial stage. All above-mentioned situations are
normal, system will resume normal state after a few minutes.

Caution: Please don't change the WEATHER adjustment in the area with
obstructions for the safety reason.

How to change vessels heading in PILOT control mode of automatic steering

First, press "Course" button to activate the function of course setting,
"HEAD" indicator and "COURSE" indicator light up at the same time, two displays
show the present heading and former setting (flashing) respectively.

Clockwise or counter clockwise turn "COURSE/ROT SETTING" setter to

increase or decrease the setting, then press the "CRSset" button again, with a
whistle of buzzer, new setting course stops flashing, and it is confirmed. Autopilot will
send out rudder order corresponding to this setting immediately, control the vessel
on the new setting course.

Remarks:
1. Confirmation (re-pressing the "CRSset" button) is necessary to put the new
setting into effect. Otherwise, display stops flashing 3 seconds later and turn
back to the former setting by itself.
2. If the difference between setting course and present course greater than 10,
"COURSE" alarm lights up and the buzzer whistles. If the difference less
than 8, "COURSE" alarm indicator goes out.

Rate of Turn Control in Automatic mode

In automatic steering, whether "PILOT" control mode or "NAVI" control mode,
besides maximum rudder movement limit (LIMIT setting), control the maximum rate
of turn could avoid the vessel's overturning also. With two safeguards, use a greater
LIMIT value to speed up the turning, while control the maximum rate of turn to avoid
vessel's overturning to improve vessel's dynamic behavior.
Setting of Maximum Rate of Turn:
Press "ROTset" button, two "ROT" indicators light up at the same time, two
displays show the present rate of turn and setting turn rate (flashing) respectively.
Clockwise or counter clockwise turn "COURSE/ROT SETTING" setter to
increase or decrease the value, press the "ROTset" button again, with a whistle of
Page 22 of 49
buzzer, "Setting Course/TurnRate" display stops flashing, the new setting is
confirmed. The autopilot sends out rudder order to control the vessel's turning
according to the two settings, maximum rudder angle and maximum rate of turn.
Displays will show the actual turn of rate and maximum turn of rate until pressing the
"Course" button.

Optimal setting of rudder angle limit and rate of turn is determined according to the
actual situation of the vessel as well as captain's opinion. The default setting of
maximum rate of turn is 99per minute when delivery by manufacturer.

Further explanation on "NAVI" control mode of automatic steering

If autopilot is connected with satellite navigational devices, such as GPS satellite
navigator or GPS chart plotter, operates according to the following steps,
A.
Set at least one goal on satellite devices according to the instruction of the
device.
B.
Check whether the yellow indicator on "NAVI" is flashing after connecting with
navigational devices, if the indication lamp does not light up, it means that no
satellite navigational information received, check the connection between the
autopilot and navigational devices.
C.
Put the "mode select switch" to "AUTO" position, press "NAVI" button, and the
green indication lamp on "NAVI" is lit up along with a whistle of buzzer.
D.
When goal data from navigational devices is received, the bearing to waypoint
shows on the "Setting course/TurnRate" display. At this moment,
The green indicator of "NAVI" lights up and yellow indicator flashes.
"AUTO" indicator lights up at the same time.
Green indication lamp of "PILOT" button is went out.

Setting of two or more goals

When there are two or more goal settings in the navigational devices, the
autopilot will receive these goal signals in order, and go forward to the setting
goal in order. When the vessels arrived on one goal and start towards the next
goal, if there is a large course change, the vessel may drift to the outside.

Handling of arriving at the last goal

When arriving at the last setting goal, vessel may keep turning around the goal.
The turning direction depends on the vessel's position of the time. Operator
should handle it according to the actual situation when approaching the goal.

How to avoid other vessels or obstructions

Page 23 of 49
It is no need to switch over the steering mode in case that there is other vessel
or obstructions, operating NFU steering handle to avoid them. Release the
handle after clear of other vessel or obstructions, system resume to the NAVI
mode automatically.

No navigational signal in NAVI control mode

If no navigational signal received 15 second after the initial setting of NAVI mode,
there is receiving error and a long whistle of buzzer. If the buzzer continues
whistling, switch to the other steering mode for a moment, and turn back to NAVI
steering mode again later, buzzer stops whistling, it means system are normal in
NAVI mode.
Notes: in NAVI mode, it can receive APB sentence information in
accordance with NMEA0183 regulation, as BT-82 autopilot has
no function of automatic correction of earth magnetic variation,
set and make the navigational device to output the true bearing
after variation correction. If there are outputs of magnetic bearing
and true bearing, True bearing has priority.

Navigational signal transmission breaks during voyage

If the satellite navigational device stops transmitting navigational signal during
the voyage, or there is malfunction of navigational controller input, vessel will
keep straight course with the destination bearing received in the last time
automatically.

Page 24 of 49
5. Optimization of Automatic Steering Performance
After implementing automatic steering, observation is still necessary whether
the vessel could keep on the order course satisfactorily. Adjusting the parameters
appropriately could optimize its performance, make it in the best condition,
adjustment is as follows

WEATHER Adjustment
WEATHER setting determines the amount of degrees the vessel may fall off
the setting course before any response is given from the rudder. The larger value
setting, the larger deviation range is allowed but with less rudder movement. The
lower setting, the smaller deviation range is allowed with higher precision to keep
the course, but the rudder movement is more frequent.

If apply automatic adjustment, autopilot will adjust it to an appropriate status

automatically, if the result is not so satisfied, ask for the professional personnel to
re-adjust the internal parameter setting of the system.

If WEATHER is set at "1" around by manual for calm sea state, the
WEATHER setting should be increased with rough sea state, and the best
setting may be determined according to the vessel's natural off-course states.

Determination of vessel's natural off course value: set the WEATHER on 1

position, observe the average deviation range relative to the course order, e.g. if
observed deviation range is about 3 degree, then set it on 3 or a position less
than 3.
If rough waters result in huge yaw, it's unnecessary to correct course
frequently. From the point the safety, set an appropriate off course limit and be
far away from surge.

RUDDER adjustment
RUDDER setting determines, how many rudder angle to correct one degree
of the deviation from setting course, for example, if vessel's heading deviates
from the setting course to the starboard with angle of 2,
If "RUDDER" points at 0.5 rudder paddle moves to port with an angle of 1
If "RUDDER" points at 1 rudder paddle moves to port with an angle of 2
If "RUDDER" points at 2 rudder paddle moves to port with an angle of 4
Usually, its on 1~1.5.
Good setting is related to vessels type, rudders function, vessels speed,
and so on, all these factors should be verified in actual practice. It is easier to
judge it in calm sea.
In calm sea, put the RUDDER at 1.2 , when vessel drifts from the
expected course by wind, a single movement of rudder could stop vessels
deviation automatically and make it turn back to expected course little by little,
the setting is appropriate as well as the best.
If the heading goes back quickly and over the setting course, rudder has to
move conversely again, therefore rudder moves over and over again, it means
Page 25 of 49
that the setting is too large, decrease the value.
If only two or more rudder movements in same direction could stop
vessels deviation, it means that the setting is too small, increase it.
The optimum setting is relevant with vessels speed, water current and
rudder effect. Larger setting for low vessel speed and small rudder effect, and
smaller setting for high vessel speed and good rudder effect, so adjust the
RUDDER as vessel's relative speed changes.

RATE adjustment
RATE is determined by the vessel's load, larger setting for full load, while
smaller setting for ballast/light-load.
After setting of optimum RATE, turn the vessel to port and starboard with a
angle of 15~20in automatic steering respectively, if vessel change it heading
quickly without excessive overshoot (no more than 3or 20% of course turning.) ,
then the setting is appropriate and system is in the best condition. If vessel bogs
down before the new course little by little without any overshoot, it means the
setting is excessive, so reduce it. If vessels overshoot is more than 3, and
overshoots occur again after re-turning, even vibration without rest, it means the
setting of differential parameter is insufficient, increase it.

Notes:
A.
If there is wave on the sea, it is possible to have somewhat big overshoot after
turning, however, the situation without any overshoot should be avoided as
well.
B.
Some small-size vessels have no overshoot even without differential
parameter when turning heading. Appropriate increase of RUDDER setting
could improve its turning ability.
C.
Some vessels may have a big overshoot after a large angle turning, and
increasing differential value makes no use as well. At this time, apply use a
larger filtering time constant, improve the speed of rudder movement
appropriately, and reduce the time between hard over to hard over to 20
seconds, even less, re-test again. If all these actions still have no effect,
replace a large rudder angle turning with several small rudder angle
turning.

LIMIT adjustment
If the vessel careened badly when turning, the setting should be decreased.
If the turning is too slow with little inclining, increase the setting. LIMIT is valid in
all control activities, that is, it also restrict possible maximum rate of turn.

ROT Adjustment

Page 26 of 49
 If the vessel careened badly when it turns at the maximum turn rate, reduce
the setting of Rate-of-Turn. If the vessel inclines little while the turn rate is too
low, increase the setting of Rate-of-Turn. If the vessel's turn rate can not reach
the setting value, check whether it is caused by small setting of rudder LIMIT.

Page 27 of 49
V. Installation instruction

The following points are important for the normal operation of the autopilot:
a. Apply the cables specified in the system wiring drawings. Cables for
installation are not supplied except for ordering.
b. Do not use the cable without performing high voltage test of the cables.
c. Dont bundle up the cables of autopilot with power cable, loudspeaker
cable, and so on. In addition, vessel's high power radio may interfere with
the autopilot each other.
d. To obtain an accurate heading from the magnetic compass, great care
should be taken to the location of the compass, in the area 1m close to
magnetic compass, there should not be other electrical instruments, active
magnet, strong magnet, or other things may affect its precision. All the
cables of large electrical current should be installed in couples, and it is
much better twisting each other. Precision of magnetic compass should be
calibrated regularly.
e. The mounting place should be convenient for operation with little vibration.
Prevent the equipment from rain and sunshine to prolong its service life.
The appropriate space must be left around the instrument for easy
maintenance.
f. Make sure that power supplied by vessel agree with the power requested
avoiding damage of the equipment.
g. Dont measure insulator resistance with high-resistance meter, because
the system applies semiconductor components.
h. The alignment procedure has been performed before the delivery. Don't
disassembly or align it wantonly. Please contact with manufacturer in case
of problems.

Installation of magnetic course Sensor CS-32

Magnetic course Sensor converts the course from magnetic compass into
electric signal, it is a very critical part, should be installed carefully.
Place the Sensor as well as its bottom to the center of magnetic compass's
bowl, heading line on the Sensor should align with the fore and aft line on the
bowl, at this position, fix the bottom to the glass of the bowl with glue. It's better
if the position is more precise.
After controller is put through, compare the readings on display with the
magnetic compass's reading, slightly adjust the position of fore and aft line
mark to improve the precision of the course repeating.

Page 28 of 49
Installation of rudder feedback FB-82
To transmit the rudder's actual position (rudder angle) to controller through
rudder feedback, make sure that the four points make a "parallelogram", the four
points are rotating center of feedback's rocker arm, rotating center of wheel shaft,
articulated point of rudder tiller and adjustable connecting rod, and articulated point
of rocket arm and adjustable connecting rod, it's nearly a rectangle when it is at
amidship.
In addition, parallelogram 's two sides should be within the adjustment range of
rocker arm and connecting rod. The right position of feedback's outer is that
feedback indicates at position "0" when the rudder is at amidship.

VI. Alignment & Testing

The operators must be familiar with the contents of instruction before

alignment, and check according to the following steps:

Alignment of steering control unit

a. Check and be sure that the components are correct connected according to
system wiring diagram.
b. Put power switch of steering stand on OFF position, put through the
master switch board, then steering stand is supplied. Open the door of
steering stand, measure at the connection terminals to confirm whether
steering stand is correctly supplied with vessels power.
c. Turn the switch of pump starter to remote, steering mode select switch on
NFU, steering place selector switch on CTRL in Bridge.
d. Put the power switch of steering stand on No.1, operation and 1# RUN
(port pump) indication lamp light up at this time.
e. Turn the handle of non-follow-up switch to Port rudder position, then
rudder move to left side, and Turn the handle to Starboard rudder, rudder
move to right side. If the movement direction is opposite, then exchange the
wiring connection of port and starboard solenoids to hydraulic system.
f.
Put power switch on No. 2, the 2# RUN" (starboard pump) indication lamp
should light up. Repeat the last step..
g. Turn helm wheel, put hand steering input on amidship, that is zero
position.
h. Turn the mode select switch to hand. Turn helm wheel respectively to left
and right side, sending out rudder order of 10, rudder should follow up it ,
the allowed error is 1 .
If hydraulic system oscillates, adjust anti-overshoot potentiometer on servo
panel. Turn the screw clockwise could improve its anti-overshoot ability. If
anti-overshoot ability is too high, then the indication lamps of active rudder
flash and rudder couldnt reach the expectation. At this time, counter
clockwise turn the screw of potentiometer to reduce its anti-overshoot ability.
System should be adjusted to a state of: rudder could follow up the rudder

Page 29 of 49
 order timely, no matter what angle is, neither overshoot nor pause. Single
flashing of active rudder indicator is allowed under special condition.
If hand steering is out of order, refer to the related contents in Trouble
Shooting.
i.
Put the steering mode select switch to "AUX" to perform the steering by
auxiliary station, and check its running with same method of NFU steering.
(auxiliary station is option)
j.
Turn "RUDDER" to position 1.2, turn steering mode selection to "AUTO".
k. Clockwise turn "COURSE/ROT SETTING" setter, make the order course 5
degree greater than vessel's actual course, rudder will move to starboard 5
degree, allowed error is 1.2 degree. Counter clockwise turn the setter, make
the order course 5 degree less than actual course, rudder will move to port 5
degree, allowed error is 1.2 degree too.

Sea trail
The sea trail is to determine the parameter setting in the automatic mode,
especially determination of RATE parameter (damping and inducing of
automatic check-the-helm (constant error compensation). These parameters should
be recorded and archived. Even replacing amplifier, sea trail is no longer need,
adjust the machine based on the records.
In order to set optimum parameters, vessel should sail at cruising speed in
calm sea. The calmer of sea state, the more accurate of results.

Preliminary setting of P.I.D time constant (P.I.D Proportion, Integral, Differential)

Before the sea trail, turn the switches to the positions listed in Table blow as per
vessel's size. These settings may change and be finalized according to the results of
the sea trail.

Filter Check-the-
Vessels RATE S Automatic
S2 helm S3
size in 1 sensitivity
Time
tons Time constants Gain
constants Time constants
0. 1 4 1. 5 125 25mV----30m
6 1. 5 125 per time
0. 1 0. 6 1. 5 125 30mV----35m
5 10 1. 5 per time
0. 5 2 10 1. 5 3 125 35mV----40mV
20 1. 5 3 125 per time
40 3 6 250
2 10 40 3 6 250 40mV----45mV
60 6 10 500 per time
100 6 15 500

Page 30 of 49
 Note: usually, Check-the-helm (S3) is 4~5 times of Rate (S1), no less than 4
times.

Set the position of individual switch according to the selected time constants,
before finalization of time constants, put the No. 1 switch of S3 to "OFF" position,
that is, integral is not induced. (The switch is on the "automatic rudder order
calculation board".)

Time Switch position

Swit
constant 1 2 3 4 5 6 7 8
ch
S1 4S 1 0 0 0 0 0 0 1
6S 0 1 0 0 0 0 0 1
10S 0 0 1 0 0 0 0 1
20S 0 0 0 1 0 0 0 1
40S 0 0 0 0 1 0 0 1
60S 0 0 0 0 0 1 0 1
100S 0 0 0 0 0 0 1 1
OFF 0 0 0 0 0 0 0 0
S2a 1. 5S 1 0 0 0
3S 0 1 0 0
6S 0 0 1 0
10S 0 0 0 1
15S 0 0 0 0
S2b 1. 5S 1 0 0 0 0
3S 0 1 0 0 0
6S 0 0 1 0 0
10S 0 0 0 1 0
15S 0 0 0 0 1
S3 OFF 0 0 0 0
125S 1 1 0 0
250S 1 0 1 0
500S 1 0 0 1

1=ON
0=OFF

Preliminary setting of external parameters in automatic steering (adjustors on the

steering control panel)
A. Clockwise turn "WEATHER" knob to "1" position,
B. Turn "RUDDER" to 1.2 position.
C. Turn "RATE" knob to 1 position when slack-load, on 4 when half-load
and on 6 when full-load.

Page 31 of 49
 D. "LIMIT" is determined by vessel's size, usually it is "20" for common
vessels, 15 for bulk cargo, oil tankers, and "10" for container, opinion of
vessel owner should be considered also.

Determination of RUDDER setting

In order to find a precise RUDDER setting in automatic steering mode,
adjustment should be performed according vessels deviation in the calm sea. Put
the WEATHER to "0.5" in advance.
First, put RUDDER" on 1.2. In automatic steering, observe the vessel's
actual off-course: when vessel drifts off planned course by wind and a single
movement of rudder could stop vessels deviation, and make it turn back to planned
course little by little, then the setting is appropriate. If vessel oscillates from left to
right following the active rudder, then reduce the setting. If only more than two
movement of rudder could stop vessels deviation, increase the setting. After getting
the optimum setting of RUDDER, it is the reference for the future operation.

General speaking, optimum setting of RUDDER is related to vessel's speed,

flow direction, it is inversely proportional to the relative speed of the vessel. Or, it is
related to rudder effect, larger setting for low vessel speed and low rudder effect,
while smaller setting for high speed and high rudder effect. In addition, vessel's load
also affects the setting, larger setting for slight load and smaller setting for full load.
Therefore, it is should be adjusted during the voyage based on these principles as
well as the vessel's condition and sea state.

Determination of internal parameter "RATE" (differential)

After setting of optimum RATE in straight voyage, turn the vessel to port and
starboard by "COURSE/ROT SETTING" setter with a angle of 15~20respectively, if
vessel change it heading quickly & smoothly without excessive overshoot (no more
than3, that is 20% of course turning.) , then the setting is appropriate and system is
in the best condition. If vessel bogs down before the new course without any
overshoot, that means the value of differential parameter is excessive, then reduce
its value. If vessels overshoot is more than 3, and overshoot occurs again after
returning, even vibration without rest, that means the setting of differential parameter
is insufficient, increase it. Turn to port and starboard for several times to test whether
the setting is optimum.
Notes:
A.
The test should be performed in calm sea. In case of smooth sea, there might
be somewhat overshoot, and there are different results in the two sides. In
order to gain a precise result, turn to port and starboard for several times
respectively and take the average. In fact, an overshoot less than 3 5
is acceptable, but no any overshoot should be avoided as well.
B.
Some small-size vessels have no overshoot even without differential
parameter when turning heading. Appropriate increase the setting of
Page 32 of 49
 RUDDER could improve its turning performance.
C.
Some vessels may have a big overshoot after a large angle turning, and
increasing differential value makes no use as well. At this time, use a larger
filtering time constant, improve the speed of rudder movement
appropriately, and reduce the time between hard over to hard over to 20
seconds, even less, re-test again. If all these actions still have no effect,
replace a large rudder angle turning with several small rudder angle
turning.

Page 33 of 49
Inducing of automatic check-the-helm (Integral)
After completion of abovementioned tests, integral can be induced. Based on
the finalized differential time constant, select the integral time constant according to
the above table, (usually, check-the-helm time constant is 4~5 times of the RATE
time constant, no less than 4 times), turn the integral switch K3 to the listed position
marked in the table, and K3-1 switch to "ON" position, afterwards, autopilot will check
the helm automatically in automatic steering to correct course deviation.

Automatic adjustment of "WEATHER" (sensitivity)

Automatic weather adjustment will change as sea state changes
automatically. As sea state changes from time to time during long voyage, settings
should be adjusted accordingly. It's easy for operation when applying automatic
weather adjustment.
Counter clockwise turn WEATHER knob to " /W.A." position, the
autopilot will adjust it automatically.
The gain calibration of automatic weather adjustment is determined during
the navigability test. It is relevant with vessels size. Large vessels should have a
large gain because of long off-course period, otherwise have a small gain. The value
of gain affects the performance in straight navigation directly. The larger gain setting,
the larger deviation range is allowed with the less rudder movement, and be more
economical. The smaller gain, the smaller deviation range is allowed, the better
course keeping capability and the more frequent rudder movement. If the rudder
movement is frequent according to overall evaluation of sailing for a time, increase
the gain appropriately, for example, make the control voltage of the WEATHER
adjustment increase by 20% after single rudder movement per time (measure the
voltage ofXJ11 to XJ0). Reduce the setting in case of large deviation range allowed.
The optimum gain calibration should be determined according to the overall
evaluation of many times voyages.
Preliminary set the automatic weather adjustment in sea trail as follows,
Turn "WEATHER" to "1" position, observe the average deviation range relative to
order course, for example, if the observed deviation range is 3 degree around, put
the "WAETHE" to "3" position or a position less than 3. Observe the vessel's
deviation range and rudder movement for 30 minutes. Then put the "WEATHER" to
automatic status, continue observing for 30 minutes, compare the deviation ranges
and rudder movements during the two 30 minutes, judge and adjust accordingly. If
there is no obvious difference, it is regarded that the setting is appropriate.

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Enclosed: setup and calibration of course repeater
Usually, all the under-mentioned contents have been done in the
factory, it is not necessary to re-set and re-calibrate unless there
be unacceptable errors.

When power is put through, course repeater starts up. The digital display
indicates 8888 at first, entering self-check. Illumination can be adjusted by the red
and green buttons under the repeater, press the red button to increase the
brightness, press the green button to decrease the brightness.
After self-check, digital display indicates " -//- ", repeater enters
automatic calibration and matching. At the beginning, the dial clockwise turn slowly,
the turning will be faster and faster till turning quickly. It pauses at the position of
"000. 0" for a short moment, then enter into normal operation, the indicated value on
the dial should be consistent with the reading on digital display.
If self-check and automatic matching is failed, it indicates "Err" on repeater's
digital display.
When entering normal operating, if there is no effective course signal received
within 3 seconds, digital display will indicate "".
Repeater receives NMEA sentence via RS-232 & RS-422 interfaces. Sentence
format should be set in the initial operation.

1. Re-matching of dial reading

Press two buttons simultaneously, digital display shows " // ", repeater
enters automatic matching procedure, after automatic matching and calibration, the
indicated value on the dial is almost consistent with the reading on the digital display.

2. Setting mode
Press the two buttons simultaneously for 5 seconds or more, release until the
display shows "SET" to enter the setting mode, press the green button again,
indication shows as following items in order by each pressing, (the sequence is
converse if press red button)

- CF - - Sentence setting mode, to select the desired sentence format

-
CHE - Dial indication verification mode, to check indication precision of dial.
C -
[-//-] - Dial calibration mode, to eliminate the average error of dial indication
-
scan - Dynamic scanning mode, to test the ability of dynamic following
-
quit - Quit the setting mode
-

Note: NMEA sentence setting is HDT when delivery, and the other three
items (CHEC, [-//-], scan) have been calibrated already before delivery,
usually, no need to adjust.

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 In the selected mode, press the red and green buttons simultaneously to
activate the mode.

3. Sentence setting: HDT, HDM/HDG

In setting mode, press red or green button till display shows "CF", press red
and green buttons simultaneously to enter the mode, at this time, display shows:
HDT or HDM/HDG
Press the red or green button until display shows HDT/HDG or HDT
When display shows the desired sentence, press two buttons simultaneously,
the sentence format is set, display shows "-CF-", and quit to the setting mode.
Press one button to select QUIT mode, then press two buttons simultaneously
to return the normal operation, or waiting about 7 seconds, the repeater will return to
normal operation status automatically.

4. Dial indication verification mode (to check the indication precision of the dial at
individual course points)
In setting mode, press red or green button until display shows "CHEC", press
the two buttons simultaneously, enters the mode of dial indication error verification:
dial return to scale "0", display shows "000.0".
Press red button or green button, the indication increases or decreases by 0.1
degree per step, and it changes faster and faster as the pressing time goes on,
release the button, the display stops at a figure, check the indication error at each
point of the dial scale, re-press to change it again.
After check all the points, press the two buttons simultaneously, confirm
completion of indication error verification, and return to the setting mode, display
shows CHEC.
Repeater will return to normal operation after 7 seconds around, or quit
immediately from quit mode either.

5. Dial calibration mode (to eliminate the average of errors of each points,
usually, it is done after completion of the product.)
In setting mode, press "red" or green button until display show "[-//-]".
Press the two buttons simultaneously, enter dial calibration mode, dial will turn
and stop at one point, digital display indicates the course value at the time, two
indications may be different.
Match the dial indication with the digital display by red or green button.

Attention: Overall consideration is important. Be sure that gap

between indicated value on the dial and display read-
out is acceptable. Otherwise, there may be big error of
dial indication at some points!

Press two buttons simultaneously again, confirm the completion of dial

calibration, return to the setting mode, then display show [-//-]. About 7 second later,
repeater returns to the normal operation, or quit immediately via "quit" mode.

6. Scanning mode
In setting mode, press the red or green button till display shows "SCAN", press
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the red and green button simultaneously to enter the scanning mode.
Dial will turn back and forth from "000. 0", it turns every 5 degrees in the
forward direction and falls back 3 degrees in the reverse the direction, to check
whether there is out-of-step. Scanning ends up with "000. 0", in case of out-of-step,
display shows "Erro".
Press two buttons simultaneously to confirm the completion of scanning, return
to the setting mode, display shows "SCAN". About 7 second later, it will return to
normal operational status, or quit immediately via "quit" mode.
Notes:
1. If digital display shows "", it is an alarm from course
detector, it means that front-end devices are in warming-up
status, or the course value is invalid.
2. Connection with other equipment via interface RS 232 is as
follows,
cable 1(yellow) for 24V;
cable 2 (green) for 0V;
cable 3 (grey) for RX+;
cable 4(magenta) for RX-;
cable 5 (brown) for grounding.
Connection with other equipment via interface RS 422 is as
follows,
cable 1(yellow) for 24V;
cable 2 (green) for 0V;
cable 3 (grey) for RX-;
cable 4(magenta) for RX+;
cable 5 (brown) for grounding.

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VII. Trouble shooting

Action for alarm

In case of alarm, switch to another pump. In due time, make further check and
remove the fault according to the table below.
" POWER" alarm
Cause A. Power for hydraulic system is lost main switchboard is
not supplied or malfunction of power circuit.
B. Pump doesnt start because the fuse or power cable is
broken.
Action A. Switch to another hydraulic system, and check the power
circuit in due time.
B. Replace with backup fuse or cable.

"PHASE" Alarm
Cause A. One phase is lost or phase sequence is mixed.
B. False alarm, it may occur in other alarm circuits as well.
Action A. Switch to another hydraulic system, check the power
cable and phase sequence, correct it in case of fault.
B. Check the contact and wire connection of the alarm detect
circuit.

"LOAD" Alarm
Cause Oil pump motor of hydraulic system is over-load.
Action A Switch to another hydraulic system for steering, check up
pump starter and hydraulic components, and reset over-load
relay.

"Liquid level" Alarm

Cause Level of hydraulic system is too low.
Action Check the level of oil tank and fill with oil.

"PRESS." Alarm
Cause Filter of hydraulic system is blocked, large pressure
difference in the filter.
Action Clean the filter and replace filter core.

"TEMP" Alarm
Cause Oil temperature of hydraulic system is too high
Action Switch to another pump, check and adjust the alarmed
hydraulic system.

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 "STICK" Alarm
Cause Hydraulic system is blocked, rudder can not act normally. (see
trouble shooting of NFU steering)
Action Fixed displacement pump system: disassemble and clean
solenoid valve, filtrate hydraulic oil to remove the impurity or
change the hydraulic oil. Or midposition spring of solenoid
valve is broken, replace it.
Variable pump system: check and repair the pump.

"COURSE" Alarm
Cause In automatic steering, difference between vessel's present
heading and setting course is greater than the permitted
value.
Action A.
Change the setting course more than 10by automatic
steering, alarm will be cleared automatically after
entering the new course.
B.
Automatic steering mode is out of order, see section of
"trouble shooting for automatic steering".

"COMPASS" Alarm
Cause Course difference between Gyrocompass and magnetic
compass is greater than 102
Action A.
Big error of magnetic compass, calibration by professional
personnel.
B. Fault of Gyrocompass or repeater, repair by experienced
personnel.

"DC24V" Alarm
Cause After start-up, 24V DC power is not supplied to steering stand.
Action Put 24V DC power switch of distribution box to "ON" position.

"CTRL PWR" Alarm

Cause The selected main power supply(380V) is lost.
A.
Hydraulic pump can not be started, the steering place
selection of starter box is wrong on "CTR in stern".
B.
The fuse core or the power cable is broken.
C.

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 Autopilot is turned off, but the 24V storage battery is not
turned off yet.
Action Switch to another power supply and remove the trouble
timely.
A. Put the operation place select switch to "CTRL in bridge".
B. Replace fuse core or backup cable.
C. Turn off the switch of 24V power in bridge distribution box.

Trouble shooting in NFU steering mode

Rudder hard over in the converse direction in NFU mode

Failure rudder moves opposite to the order
Cause Wrong wiring connection
Action Exchange the cables to solenoids for port rudder and
starboard rudder.

NFU steering out of order or now and then

Failure NFU steering is unavailable, or hard over just after starting.
Cause A.
Solenoid winding is open.
B.
Control circuit of solenoid winding is open.
C.
Solenoid core is blocked.
Action A.
Measure the resistance of solenoid winding, replace it in
case of open winding.
B.
Check the fuse core & cable connection of solenoid control
circuit in the steering box of Steering gears room, correct
them in case of open or bad contact.
C.
If the valve is blocked, clean it or change hydraulic oil if
necessary.

Rudder runs away to single direction in NFU steering

Failure Rudder runs away to the single direction, or hard over, while
the hand steering is normal.
Cause Midposition spring of solenoid or hydraulic valve is broken or
ineffective.
Action Check and replace the midposition springs.

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Trouble shooting for hand steering

Rudder runs hard over in converse direction in hand steering

Failure Rudder moves opposite to order till hard over.
Cause Converse signal from rudder feedback, or wrong wiring
connection of rudder feedback.
Action Exchange the two cables to feedback exciting coils.

Rudder moves in converse direction and be able to stop in hand steering

Failure Rudder stops at the opposite side
Cause Invert signal output of feedback, wrong cable connections to
two solenoid windings.
Action Exchange two cables to feedback's exciting coils, and
exchange two cables to solenoids of port and starboard
control as well.

Hand steering is out of order

Failure 1. NFU steering is out of order as well.
2. Hand steering runs away but the NFU steering is normal.
Cause 1. NFU steering is out of order.
2. No rudder feedback signal, or fault of follow-up amplifier.
Action 1. See section of NFU steering trouble shooting
2. Check the screws of feedback's input/output terminal and
tighten them if loosing. Check and replace the broken
cable, check and remove malfunction of amplifier or
replace it.

Hydraulic system oscillates or sluggish response in hand steering

Failure Rudder at both sides oscillates or active rudder indicator
flashes but rudder is sluggish.
Cause 1. There is air in the hydraulic system, too much output flow
of oil pump resulting in over high speed of rudder
2. Anti-overshoot adjustment is out of order.
Action 1. Check and remove the air in the hydraulic system, reduce
the output flow of oil pump, increase the time from hard over
to hard over, ( but no more than 28 seconds.)
2. Re-adjust potentiometer for anti-overshoot, increase
system damping by clockwise turning, otherwise, it decrease.

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 Only one side hydraulic system oscillates or sluggish
Failure Only one side rudder oscillates or active rudder indicator
flashes but rudder is sluggish.
Cause Rudder speed of two systems are not consistent.
Action Adjust the output flux from hydraulic pumps, make two
speeds be equal with a difference lower than 2 second. Re-
adjust anti-overshoot.

No following for small rudder angle in hand steering

Failure Small rudder angle can be followed, following accuracy is
poor.
Cause Improper gain adjustment of rudder order amplifier, or loose
connection of rudder feedback, or too big dead band.
Action Check the gains of rudder feedback amplification circuit,
NFU order amplification circuit, and NFU integrated
amplification circuit, and correct it in case of problem.
Correct and fasten the position of rudder Sensor in feedback.

Big follow error of hand steering

Failure Small rudder angle can be followed, but following accuracy is
poor.
Cause Improper link installation of rudder feedback's parallelogram
unit
Action Adjust the unit to meet the requirements of parallelogram.

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Trouble shooting for automatic steering

Automatic steering is out of order

Failure Hand steering is out of order as well.
Cause Hand steering is out of order.
Action Remove the failure of hand steering.

Rudder is hard over in automatic steering

Failure Hand steering is normal while wheel hard in automatic
steering.
Cause Fault of automatic rudder order circuit.
Action Check & fasten the screws of input and output circuit of
rudder order Sensor by experienced service personnel.

Heading swings in automatic steering

Failure Vessel's heading swings back and forth, rudder moves to
port and starboard respectively.
Cause Setting of rudder angle ratio for automatic steering is too
large
Action Reduce the setting, usually it is about 1.2

Heading is swings in automatic steering

Failure Vessel swings frequently with little rudder movement.
Cause WEATERH(Sensitivity) setting is too large
Action Calm sea: 0. 6~1. 5
Smooth sea: 1.5~3
Heavy weather: 3~5

Unable to enter new course quickly & smoothly in automatic steering

Failure When turning in automatic steering, heading exceeds the
new course 5 and more, then vacillates around new course,
and rudder stops before the new course.
Cause RATE(differential) setting is improper.
Action Reset "RATE" according to the section "automatic steering "
& "sea trail"

Rudder does work in automatic steering

Failure Rudder do not act even the deviation from setting course is
more than 5.
Cause No course input
Action Check course input circuit or repair by experienced
personnel.
Note: steering controller adopts integrated circuit and electric components, do not
attempted repair by yourself. In case of complex failure, please contact with
manufacturer, and get experienced professional for repair. During maintenance, be

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sure the power is switched off when plugging or inserting printed circuit board,
avoiding further damage.

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VIII. Maintenance

A.
As the equipment has many kinds of steering modes, please operate in each
steering mode before every sailing and be sure that all steering modes are
effective, and the system is in good condition.
B.
When automatic steering, operator should keep a close eye on sea state, trust
equipment but do not just rely on it to avoid incident occurrence. Usually,
operator should know whether the equipment is in normal operation by
watching all kinds of indicating lights.
C.
As for operator, routine maintenance only means cleaning instrument and
replacing the vulnerable objects timely, such as: illumination lamps, fuses,
etc. backup illumination lamps and fuses are stored in the spare parts box.
D.
Check the screws of the connection contact every six month, if the screws loose,
tighten them. Check the contact of follow-up steering switch for ablation,
polish or replace it according to its degree.
E.
Overall maintenance by qualified and experienced person should be done every
two years.

Daily maintenance

Magnetic compass
Lubricate the movable part of gimbal ring, because salt may adhere to its
surface and affect its smooth turning. In case of vessel's long-term berthage, it is
recommended to take it down and put it in warehouse, or cover with sun shield to
prolong its the service life.

Magnetic sensor
Magnetic sensor adopts thin & soft conductor wire to avoid interference with
magnetic compass. Caution: do not contact it with other metal part, otherwise, it
may result in damage of the wire outer and malfunction of the automatic steering.
In case of vessel's long-term berthage, it is recommended to take it down and keep
it with magnetic compass in warehouse.

Course repeater
Whether routine maintenance or repair, the whole set of repeater should be
replaced if display is in confusion.

Rudder feedback
Feedback is installed at a place with the most strong vibration on vessel and
the worst ambient environment. Feedback is a very critical unit, in case its damage,
hand steering, automatic steering, rudder indication are out of order. Before leaving
the port, check whether the ball junction and fixed part are loose. Grease monthly
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 to those moving in and out part, e.g. ball junction.

Control unit
Regular check plugs, sockets, connecting terminals whether there is rust, insulation
damage, poor contact, loose screws, etc.

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IX. Spare Parts

1. Spare parts for autopilot

A. Mechanical parts
1. reset spring (for reset switch) 1 piece
2. inner hexagonal spanner 1 set
B. Fuse core
1. Fuse RL98 16 3A 5 pieces
2. Fuse RL98 16 2A 5 pieces
3. Fuse RL98 16 1. 5A 5 pieces

2. Spare parts for hydraulic pump starter

1. Power indication lamp 380V (White) 1 piece
2. Indication lamp 380V Green 1 piece
3. Indication lamp 380V Yellow 1 piece
4. Main contactor 380V 1 piece
5. Intermediate relay 380V 1 piece
6. Fuse RL98 16 2A 5 pieces

X. Warranty

It is guaranteed for one and a half year from the date of delivered by
manufacturer, or one year from the date delivered by shipyard, and its counted on
the earlier one. During this period, manufacturer will repair or replace defective
components free of charge, however, guarantee does not cover the damage or
malfunction not caused as a result of manufacturer's responsibilities.

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Appendix

1. BT-82 Autopilot - Outline & Mounting

BT-82 Autopilot Outline & Mounting

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2. CS-32 Magnetic Course Sensor - Outline & Connection o

3. FB-82 Rudder Feedback - Outline

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4. Steering Box - Outline & Dimension

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5. Starter - Outline & Dimension

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6. Wiring Diagram - Steering Stand

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Page 53 of 49
7. Wiring Diagram SGC Steering Box

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8. Wiring Diagram Port Starter

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9. Wiring Diagram Starboard Starter

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10. System Wiring Diagram

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Page 58 of 49