B&G H-RANGE PILOT User Manual
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B&G H-RANGE PILOT User Manual

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H-RANGE PILOT
USER MANUAL
Premier Way
Abbey Park, Romsey
Hampshire, SO51 9AQ, UK
Tel: (+44) 01794 518448
Fax: (+44) 01794 518077
e-mail:
sales@BandG.com
© B&G Ltd. 2003
The copyright of this manual is the property of B&G Ltd.
HB-0842-02

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Ron Richard
April 14, 2025

How do I calibrate my rudder

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1 comments:
Mr. Anderson
April 14, 2025

To calibrate the rudder on a B&G H-RANGE PILOT, follow these steps:

1. Install and Check Rudder Reference Sensor (RRF):
- Mount the RRF on a flat surface near the tiller arm or steering quadrant.
- Ensure the sensor arm is near the cable entry point when the helm is amidships.
- The arm should move at least 90° from port to starboard.
- Verify at least a 1-volt change between the blue (0V) and green (signal) wires.

2. Perform Rudder Hard-Over Time Calibration:
- Ensure the boat is stationary. If using hydraulic steering, engines must be running.
- Select "RUD T" from the menu.
- Set RUD T to ON and press Enter to start.
- The Pilot will move the rudder from port to starboard to measure the time.
- Keep clear of the steering mechanism during this test.

3. Check Rudder Movement via Pilot:
- Engage the Pilot.
- Use << >> keys to move the rudder in large steps (~3° each).
- Use < > keys to move the rudder in small steps (~1° each).
- Press MID to return rudder to amidships.

4. Check for Backlash:
- With Pilot engaged, try to move the rudder with the wheel.
- Backlash should be less than 1°.
- Fix any backlash issues immediately.

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Summary of Contents for B&G H-RANGE PILOT

  • Page 1 H-RANGE PILOT USER MANUAL Premier Way Abbey Park, Romsey Hampshire, SO51 9AQ, UK Tel: (+44) 01794 518448 Fax: (+44) 01794 518077 e-mail: sales@BandG.com © B&G Ltd. 2003 The copyright of this manual is the property of B&G Ltd. HB-0842-02...
  • Page 2 H-Range Pilot User Manual H-RANGE PILOT USER MANUAL CONTENTS Product Liability and Safety Warnings Record of Amendments PART 1 INTRODUCTION PART 2 OPERATING INFORMATION PART 3 CALIBRATION PART 4 INSTALLATION INFORMATION PART 5 OPTIONS PART 6 DIAGNOSTIC DATA HB-0842-02...
  • Page 3 H-Range Pilot User Manual PRODUCT LIABILITY AND SAFETY WARNINGS PRODUCT LIABILITY - Brookes and Gatehouse Ltd. accept no responsibility for the use and/or operation of this equipment. It is the users’ responsibility to ensure that under all circumstances the equipment is used for the purposes for which it has been designed.

  • Page 4: Table Of Contents

    H-Range Pilot User Manual Part 1 - Introduction PART 1 - INTRODUCTION CONTENTS Para Page SYSTEM OVERVIEW PILOT OPERATION CONTROLLING THE PILOT PILOT DISPLAY HAND-HELD CONTROLLER JOYSTICK MAN OVERBOARD BUTTON ILLUSTRATIONS Fig No Page Pilot Display Hand-held Controller Joystick Man Overboard Button...
  • Page 5 H-Range Pilot User Manual Part 1 - Introduction Intentionally Left Blank HB-0842-02...

  • Page 6: System Overview

    The H-Range Pilot can be used for both sail and powerboats that have a Hydra 2000, Hercules 2000 or HS2000 System installed. If the relevant sensor data is available, the Pilot offers the following...

  • Page 7: Pilot Operation

    (d) Power Steering - Allows the Pilot direct control of the steering. (e) Steering to Optimum Wind Angle - This option is only available when a Hercules Performance Processor is installed. Other options for the H-Range Pilot include the following: (a) Hand-held Controller. (b) Joystick Steering. (c) Man Overboard...

  • Page 8: Pilot Display

    H-Range Pilot User Manual Part 1 - Introduction PILOT DISPLAY Fig 1.1 - Pilot Display The backlit Liquid Crystal Display (LCD) shows the following information: (a) Large Digits (top centre) - The current heading as provided by the Pilot Compass or Instrumentation System.

  • Page 9: Hand-Held Controller

    H-Range Pilot User Manual Part 1 - Introduction (f) Red Off Key (top right of keypad) - This key disengages the Pilot and returns the boat to Manual Steering. It has no other function. (g) Lights Key (bottom right of keypad) - This key turns...

  • Page 10: Joystick

    H-Range Pilot User Manual Part 1 - Introduction (c) Auto/Resume - Pilot engage and return to course. (d) Off - Pilot disengage. JOYSTICK 36.0 View from underside dia 21.0 mm 48.0 mm Forward indicator marks 70. 0 mm dia 40.0 mm 45.0 mm...

  • Page 11: Man Overboard Button

    H-Range Pilot User Manual Part 1 - Introduction (b) Proportional Steering (Prop) - The position of the rudder follows the position of the Joystick. When the Joystick returns to the central position the rudder returns to its initial position. MAN OVERBOARD BUTTON Fig 1.4 - Man Overboard Button...
  • Page 12 H-Range Pilot User Manual Part 2 - Operating Information PART 2 - OPERATING INFORMATION CONTENTS Para Page SWITCHING ON MODE SELECTION 2.2.1 Introduction 2.2.2 Mode Selection STEER TO COMPASS 2.3.1 Introduction 2.3.2 Selecting Compass Mode 2.3.3 Engaging the Pilot 2.3.4 Dis-engaging the Pilot 2.3.5...

  • Page 13: Joystick

    H-Range Pilot User Manual Part 2 - Operating Information CONTENTS (Contd) Para Page POWER STEER 2-18 2.6.1 Introduction 2-18 2.6.2 Selecting Power Steer Mode 2-18 2.6.3 Engaging the Pilot 2-19 2.6.4 Dis-engaging the Pilot 2-19 2.6.5 Fine Rudder Adjustments 2-19 2.6.6...

  • Page 14: Switching On

    Part 2 - Operating Information PART 2 - OPERATING INFORMATION SWITCHING ON The H-Range Pilot has two power supplies (instrument and heavy duty) connected via circuit breakers and/or fuses. The Pilot Computer and Pilot Displays are powered via the FastNet data cable and share the same source of supply as the Hydra, Hercules or HS2000 Instrument System.

  • Page 15: Mode Selection

    H-Range Pilot User Manual Part 2 - Operating Information MODE SELECTION 2.2.1 Introduction The Pilot software automatically determines which modes of operation are available depending on whether the vessel is a powerboat or a sailboat. The Pilot also receives Waypoint or Wind data via the FastNet databus from either a compatible position fixer or the Masthead Unit.

  • Page 16: Selecting Compass Mode

    H-Range Pilot User Manual Part 2 - Operating Information 2.3.2 Selecting Compass Mode Press the < Key adjacent to the MODE legend until COMPS appears on the top line. 2.3.3 Engaging the Pilot (1) From the Pilot Display and with the boat steered on the desired course, press the Key adjacent to the COMPS legend.

  • Page 17: Changing The Pilot Course

    H-Range Pilot User Manual Part 2 - Operating Information 2.3.5 Changing the Pilot Course Note The Pilot can be immediately disengaged and the steering returned to manual control by pressing the Red Off Key on any Pilot Display or Hand-held Controller.

  • Page 18: Pre-Setting The Pilot Course

    H-Range Pilot User Manual Part 2 - Operating Information (3) Temporary Changes (Dodging) - At any Pilot display press the > Key adjacent to the 10 legend to change the Pilot course to starboard by 10 . When the key is pressed, the last course is stored in the Pilot Computer course memory.

  • Page 19: Steer To Wind Introduction

    H-Range Pilot User Manual Part 2 - Operating Information (2) Press the < Key (Decrease) and > Key (Increase) adjacent to the < < > > legend to alter the Pilot legend to pre-set the Pilot course, displayed on the lower digits.

  • Page 20: Selecting Wind Mode

    H-Range Pilot User Manual Part 2 - Operating Information 2.4.3 Selecting Wind Mode (1) At the Pilot Display press the key adjacent to the MODE legend until WIND appears on the top line. The Apparent Wind Angle (AWA) displayed on the bottom digits is the same as the displayed APP W/A on the Instrument System.

  • Page 21: Dis-Engaging The Pilot

    H-Range Pilot User Manual Part 2 - Operating Information 2.4.5 Dis-engaging the Pilot (1) At any Pilot Display press the Red Off Key. The Pilot disengages and returns to manual steering. (2) At the Hand-held Controller press the Red Off Key.
  • Page 22 H-Range Pilot User Manual Part 2 - Operating Information Multiple key operations are added together to give the required wind angle change, e.g. for a 5 ‘target’ wind angle change press the 1 button 5 times. (b) Coarse Adjustments - At any Pilot Display press the <...

  • Page 23: Auto Tack

    H-Range Pilot User Manual Part 2 - Operating Information (2) Press the < > Keys adjacent to the <<>> legend to alter the wind angle displayed on the lower digits. (3) Press the key adjacent to the WIND legend to engage the Pilot on the User Defined Wind Angle.

  • Page 24: Auto Gybe

    H-Range Pilot User Manual Part 2 - Operating Information 2.4.9 Auto Gybe The Pilot is also able to indicate when it is possible to execute a Pilot controlled gybe. When the Gybe Key is pressed the boat will be steered on to exactly the same Target AWA, but on the opposite tack.

  • Page 25: Steer To Waypoint Introduction

    H-Range Pilot User Manual Part 2 - Operating Information (2) The appropriate NMEA sentences are selected and set to be transmitted. The minimum data requirement is XTE (cross track error); however, XTE and Bearing to Waypoint give the best steering performance. For Pilot operation select any of the following: RMB (best option), XTE, APA, or APB together with BWR or BWC.

  • Page 26: Selecting The Waypoint Mode

    H-Range Pilot User Manual Part 2 - Operating Information USER TIP Position fixer errors can cause steering inaccuracy. Always maintain a log and position plot on an up-to-date chart. Also, remember to check that the Pilot course (Waypoint to Waypoint) will steer the boat clear of any obstacles, taking into account the effects of tide.

  • Page 27: Dis-Engaging The Pilot

    H-Range Pilot User Manual Part 2 - Operating Information 2.5.4 Dis-engaging the Pilot (1) At the Pilot Display press the Red Off Key. The Pilot immediately disengages and returns to manual steering. (2) At the Hand-held Controller press the Red Off Key.

  • Page 28: Returning To Original Course

    H-Range Pilot User Manual Part 2 - Operating Information 2.5.6 Returning to Original Course (1) At the Pilot Display, press the key adjacent to the LAST legend to resume the last course. (2) At the Hand-held Controller press the Auto/Resume Key to return to the original course.

  • Page 29: Power Steer

    H-Range Pilot User Manual Part 2 - Operating Information USER TIP Allow a time margin for the next Waypoint bearing to stabilise before pressing the next key. Note The Bearing to Waypoint must be supplied via the NMEA interface for this function to operate; i.e. use one of the following NMEA sentences: APB, BWC, BWR, and RMB.

  • Page 30: Engaging The Pilot

    H-Range Pilot User Manual Part 2 - Operating Information 2.6.3 Engaging the Pilot Note The rudder should be in the amidships position (or the position at which the boat steers a straight course) before the Power Key is pressed. (1) At any Pilot Display, press the key adjacent to the POWER legend to engage the Pilot.

  • Page 31: Coarse Rudder Changes

    H-Range Pilot User Manual Part 2 - Operating Information USER TIP Multiple operations of the keys are added together to give the required rudder change. 2.6.6 Coarse Rudder Changes (1) At the Pilot Display press the < > Keys adjacent to the <<...

  • Page 32: Engaging The Pilot

    H-Range Pilot User Manual Part 2 - Operating Information There are two joystick steering options available to the helmsman: (a) Normal Steering (Norm) - The rudder moves in the direction of the joystick. When the joystick returns to the central position the rudder movement stops. The greater the movement of the joystick, the faster the response of the rudder.

  • Page 33: Dis-Engaging The Pilot

    H-Range Pilot User Manual Part 2 - Operating Information 2.7.3 Dis-engaging the Pilot (1) To dis-engage the Pilot when in Joystick mode press the Joystick Button and the boat will return to manual steering. (2) At the Pilot Display press the Red Off Key. The Pilot disengages and returns to manual steering.

  • Page 34: Set-Up Options

    H-Range Pilot User Manual Part 2 - Operating Information SET-UP OPTIONS The Hydra and Hercules Pilots have eleven common set-up options, however if a Halcyon Gyro Stabilised Compass and its associated processor are installed into the pilot system, additional set-up options become available. All set-up options are used to...

  • Page 35: Manual Response Set-Up (Resp)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.1 Manual Response Set-Up (RESP) The RESP set-up controls the response of the steering. Different selections are available dependent on whether the heading source is from the Halcyon 2000 Compass or a B&G Halcyon Gyro compass.

  • Page 36: Mode Set-Up (Mode)

    H-Range Pilot User Manual Part 2 - Operating Information To set-up RESP: (1) Press the key shown until RESP is displayed. (2) Press the key shown to scroll through the list of RESP options. NORM ECON PERF 1 PERF 2...

  • Page 37: Automatic Response Set-Up (Aresp)

    H-Range Pilot User Manual Part 2 - Operating Information To set-up MODE: (1) Press the key shown until desired MODE is displayed. (2) Press the key shown to scroll through the list of MODE options. (2) When the required mode is displayed press the key adjacent to the ENTER legend.
  • Page 38 H-Range Pilot User Manual Part 2 - Operating Information (c) NORM – Normal: in this mode, the pilot will respond to moderate changes in environmental state before altering its response rate. (d) SPORT – in this mode, the pilot will be most...

  • Page 39: Recovery Mode Sensitivity (Recov)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.4 Recovery Mode Sensitivity (RECOV) This function is only available when a Halcyon Gyro Stabilised Compass is connected to the system. Recovery Mode allows the user to select the sensitivity that allows the pilot to react to unexpected events, for example sudden wave or wind shifts.

  • Page 40: Speed Set-Up (Speed)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.5 Speed Set-Up (SPEED) The SPEED set-up allows the source used for speed data to be selected. There are three options available: (a) B SPD - Boat speed from a speed sensor (default).

  • Page 41: Pilot Display

    H-Range Pilot User Manual Part 2 - Operating Information (3) When B SPD or SOG are selected, press the key adjacent to the ENTER legend. Continue with set-up or press the key adjacent to the EXIT legend to return to the normal Pilot display.

  • Page 42: Compass Damping Set-Up (C Dmp)

    H-Range Pilot User Manual Part 2 - Operating Information (2) Press the key shown to select the display function of the bar display when the Pilot is engaged. (3) When the required display function is displayed press the key adjacent to the ENTER legend. Continue with set-up or press the key adjacent to the EXIT legend to return to the normal Pilot display.

  • Page 43: Nmea Source Set-Up (N Src)

    H-Range Pilot User Manual Part 2 - Operating Information (2) Use the keys shown to adjust the value within the range 0 to 99 seconds. (3) When the required value is displayed press the key adjacent to the ENTER legend. Continue with set-up or press the key adjacent to the EXIT legend to return to the normal Pilot display.
  • Page 44 H-Range Pilot User Manual Part 2 - Operating Information Note When more than one of the same type of NMEA position fixer is connected, i.e. two GPS receivers, then the number following the device identifier, e.g. GP 96, determines which GPS is supplying the NMEA data.

  • Page 45: Course Alarm Set-Up (Crs A)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.9 Course Alarm Set-Up (CRS A) The CRS A set-up enables the Course Alarm facility. The Pilot will sound an alarm (if an audible alarm is fitted to the instrument system) and all the system displays flash a warning when the Pilot off course error is greater than the value set.

  • Page 46: Watch Alarm Set-Up (Watch)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.10 Watch Alarm Set-Up (WATCH) The WATCH set-up enables the watch alarm facility. The Pilot will sound an alarm (if an audible alarm is fitted to the Instrument System) and cause all the system displays to flash a warning at a pre-set time interval to keep the helmsman and crew alert.

  • Page 47: Back Lighting Set-Up (Light)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.11 Back Lighting Set-Up (LIGHT) The LIGHT set-up alters the LCD backlighting colour for all Pilot Displays and FFDs connected to the system. There are two selections: (a) RED (default). (b) GREEN.

  • Page 48: Joystick Set-Up (Jystk)

    H-Range Pilot User Manual Part 2 - Operating Information 2.8.12 Joystick Set-Up (JYSTK) The JYSTK set-up selects the joystick steering, see the joystick section of this manual for details about the different steering modes. There are two selections: (a) NORM - Normal steering mode (default).

  • Page 49: Pilot Information On Ffd

    H-Range Pilot User Manual Part 2 - Operating Information PILOT INFORMATION ON FFD The Hydra or Hercules Instrument System FFD (full function display) can be configured to display a limited range of Pilot information. This information is accessed via the Pilot Menu that only appears when a Pilot is connected.

  • Page 50: Man Overboard Facility

    H-Range Pilot User Manual Part 2 - Operating Information 2.10 MAN OVERBOARD FACILITY The Man Overboard Button (MOB) is an optional extra that activates the Pilot's Man Overboard alarm procedure. The MOB can be used whether the Pilot is engaged or disengaged.

  • Page 51: Manual Recovery (All Boats)

    H-Range Pilot User Manual Part 2 - Operating Information 2.10.2 Manual Recovery (All Boats) (1) Press the MOB as soon as the person is lost overboard. The alarm will sound (if fitted) and the display will show the Man Overboard message. The Pilot display and the FFDs will now show the bearing and distance to the person overboard.
  • Page 52 H-Range Pilot User Manual Part 2 - Operating Information (3) Maintain a lookout and keep visual contact with the person in the water. Reduce the boat speed to LESS THAN 8 knots. Ensure that the area is clear of other boats and obstacles.
  • Page 53 H-Range Pilot User Manual Part 2 - Operating Information Intentionally Left Blank HB-0842-02 2-42...
  • Page 54 H-Range Pilot User Manual Part 3 - Commissioning and Calibration PART 3 - COMMISSIONING AND CALIBRATION CONTENTS Para Page INTRODUCTION TO PILOT COMMISSIONING 3.1.1 H-Range Pilot Commissioning 3.1.2 Pilot Installation Check List 3.1.3 Parameters to be Set COMMISSIONING MODE SELECTION 3.2.1...
  • Page 55 H-Range Pilot User Manual Part 3 - Commissioning and Calibration CONTENTS (Contd) Para Page 3.4.16 Setting the Boat Lag Value 3-24 ILLUSTRATIONS Fig No Page Magnetic DIP Angle Corrections 3-11 Boat Lag Response 3-23 TABLES Table No Page Compass Data...

  • Page 56: Introduction To Pilot Commissioning

    INTRODUCTION TO PILOT COMMISSIONING 3.1.1 H-Range Pilot Commissioning Before the H-Range Pilot can be used, it is necessary to carry out commissioning tests. This encompasses the setting and calibration of various parameters, installation and functional checks of the Pilot System equipment. These items are listed below in Paragraph 3.1.2.
  • Page 57 H-Range Pilot User Manual Part 3 - Commissioning and Calibration Ram free to move side to side and up and down. Reservoir at highest point if ram split. For Size Three Rams only: The reservoir has been fixed to a bulkhead above the ram and pump.
  • Page 58 H-Range Pilot User Manual Part 3 - Commissioning and Calibration Linkage has not been over extended. No slack or backlash in the linkage. Linkage does not foul when rudder moved hard over to hard over. Arm moves through at least 90° when rudder moved hard over to hard over (there must be at least a 1.0V difference between the end stops).

  • Page 59: Parameters To Be Set

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.1.3 Parameters to be Set The following is a list of the parameters that have to be set during commissioning. They are selected by pressing the keys indicated on the diagrams while in commissioning mode. Each parameter is...

  • Page 60: Commissioning Mode Selection

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration COMMISSIONING MODE SELECTION 3.2.1 Entering Commissioning Mode Notes The autopilot must be in STANDBY to carry out this operation. If it is the first time the Pilot has been commissioned, SELCT will be displayed instead of SAIL, PWR P or PWR D.

  • Page 61: Commissioning/Calibration Alongside

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration COMMISSIONING/CALIBRATION ALONGSIDE The following parameters should be set before a sea trial: B TYPE Select boat type: Sail, Power P, Power D H SRC Heading Source, compass data selection H OFF...

  • Page 62: Heading Source (Compass) H Src

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.3.3 Heading Source (Compass) H SRC The Heading Source setting defines the source for compass data. This setting is determined by the H-Range Instruments or the H- Range Pilot System.

  • Page 63: Heading Offset (Compass Alignment) H Off

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.3.5 Heading Offset (Compass Alignment) H OFF The Compass Alignment electronically compensates for the misalignment between the autopilot’s fluxgate compass and the Earth’s magnetic field. The boat’s actual heading must be known; use a calibrated bowl compass or hand-held compass for reference.

  • Page 64: Rudder Drive Type (Drive)

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration Press Enter to store the value. Fig 3.1 Magnetic DIP Angle Corrections 3.3.9 Rudder Drive Type (Drive) Note Depending upon the type of rudder drive unit fitted, the Pilot controls the rudder drive motor in different ways; this optimises the autopilot steering response.

  • Page 65: Setting The Rudder End Stops

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.3.11 Setting the Rudder End Stops Before the Pilot can be used, the position of the rudder end stops must be entered. Notes If the boat is equipped with hydraulically power assisted steering, the engines must be running whilst setting the end stops.
  • Page 66 H-Range Pilot User Manual Part 3 - Commissioning and Calibration RUD S - Setting the Starboard End Stop Select RUD S from the menu. Turn the wheel until the rudder is hard over to Starboard. Change the OFF legend to ON using the adjacent keys.
  • Page 67 H-Range Pilot User Manual Part 3 - Commissioning and Calibration RUD T - Rudder Hard-Over Time To finish the rudder end stop commissioning procedure the autopilot must calculate the rudder hardover Port to hardover Starboard time. The following points must be...

  • Page 68: Setting The Boat Length (B Len)

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.3.12 Setting the Boat Length (B LEN) The boat’s waterline length in Metres must be entered into the autopilot for it to steer accurately. Select B LEN from the menu.

  • Page 69: Verify Rudder Power Drive

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration The commissioning sea trial should be carried out under power in open water on a calm day. The procedures for the remainder of the commissioning involve continual course and speed changes, it is therefore important that a constant look out is maintained.

  • Page 70: Selecting Power Steer Mode

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration This facility could be used in an emergency if the normal manual steering system became defective, e.g. a broken steering quadrant cable or control rod. It can also assist with diagnosis of faults in the...

  • Page 71: Calibrating The Pilot Compass

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration Use the << >> Keys to move the rudder, check that the Pilot can move the rudder by large amounts, verify by watching the rudder angle on the display, each press should give approximately 3 rudder movement.

  • Page 72: Setting The Heading Offset Value (H Off)

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration With the speed below 5 knots, turn the boat through 360 upto a maximum of 720 at a rate of turn not greater than 2 per second. The display will show the amount of turn completed so far in degrees.

  • Page 73: Setting The Speed Calibration Value

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration All B&G paddle wheel type speed sensors are compatible. The Hertz/Knot value is entered into the system to ensure the autopilot steering response is controlled with reference to boat speed. The default Hertz/Knot value is 3.80;...

  • Page 74: Checking Rudder Gain Learning

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.4.11 Checking Rudder Gain Learning Steer the boat onto a suitable heading, allow time for the boat to settle on this course. Engage the pilot in COMPS (compass) mode. AT A SPEED NOT EXCEEDING 15 KNOTS,...

  • Page 75: Setting The Rudder Gain Value

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration Observe the performance of the autopilot when changing course. The rudder gain value is inversely proportional, therefore, if the rate of turn is too SLOW, REDUCE the value of rudder gain and the Pilot will use more rudder.

  • Page 76: Boat Lag Value

    H-Range Pilot User Manual Part 3 - Commissioning and Calibration 3.4.14 Boat Lag Value Boat Lag is the time taken for the boat to respond to changes in helm. For example, heavy displacement hulls require a larger value for boat lag.
  • Page 77 H-Range Pilot User Manual Part 3 - Commissioning and Calibration Boat Type Factory Set Value Typical Values Sail Boats 0.3 to 1.0 Power Boats 0.3 to 1.0 Table 3.3 Boat Lag Value Table Note The factory set value is selected by setting Boat Type and Rudder Drive Type during commissioning.
  • Page 78 H-Range Pilot User Manual Part 4 - Installation Information PART 4 - INSTALLATION INFORMATION CONTENTS Para Page CABLE AND CONNECTION INFORMATION 4.1.1 EMC Compliance 4.1.2 General Wiring Notes 4.1.3 Pilot Drive Unit Cables 4.1.4 ACP Unit Terminal Details 4.1.5 Clutch Voltage Selection 4.1.6...

  • Page 79: Contents (Contd)

    H-Range Pilot User Manual Part 4 - Installation Information CONTENTS (Contd) ILLUSTRATIONS Fig No Page ACP Unit Terminal Details DIP Switch Location Network and Alarm Connections Pilot Display Connections MOB, Joystick, Hand-held Controller Connections 4-10 Hydraulic Ram Drive Connections 4-11...
  • Page 80 H-Range Pilot User Manual Part 4 - Installation Information PART 4 - INSTALLATION INFORMATION CABLE AND CONNECTION INFORMATION 4.1.1 EMC Compliance B&G equipment is designed to be operated in leisure craft. Every care has been taken in the design and testing to ensure compliance with the European EMC Directive.
  • Page 81 H-Range Pilot User Manual Part 4 - Installation Information All cables should be routed at least 1m/3ft from cables or components that carry or generate high currents, e.g. alternators, starter motors and cabling, trim-tab cables, etc. To minimise interference avoid routing Network cables alongside...
  • Page 82 H-Range Pilot User Manual Part 4 - Installation Information 4.1.4 ACP Unit Terminal Details - + - DRIVE DRIVE SUPPLY SUPPLY Fig 4.1 ACP Unit Terminal Details Wire Colour Table Violet Black Yellow Blue Orange Brown White Green Blank Silver N/C Table 4.3 Wire Colour Coding/Abbreviations...
  • Page 83 H-Range Pilot User Manual Part 4 - Installation Information 4.1.5 Clutch Voltage Selection The ACP Computer Unit can output different clutch/solenoid voltages depending upon the size of the rudder drive unit fitted. The clutch/solenoid valve is only required for rams or rotary drive units.
  • Page 84 H-Range Pilot User Manual Part 4 - Installation Information 4.1.6 Dip Switch Location Fig 4.2 DIP Switch Location HB-0842-02...
  • Page 85 H-Range Pilot User Manual Part 4 - Installation Information ACP WIRING CONNECTIONS 4.2.1 Network and Alarm Connections - + - + DRIVE DRIVE SUPPLY SUPPLY JUNCTION BOX 288-00-001 Connect like NETWORK CABLE colours together 135-0A-130 (10m/30ft) To the other units connected...
  • Page 86 H-Range Pilot User Manual Part 4 - Installation Information 4.2.2 Pilot Display Connections Junction Box 288-00-001 Connect like colours together To other units on the Fastnet Network. Network Cable 135-0A-130 (10m/33ft) Note: The extreme ends of the Fastnet Network should be terminated by connecting terminators between the white and green data wires.
  • Page 87 H-Range Pilot User Manual Part 4 - Installation Information 4.2.3 MOB, Joystick, Hand-held Controller Connections - + - + DRIVE DRIVE SUPPLY SUPPLY Joystick and Button Man Overboard 545-00-060 Button (MOB) 302-00-007 Hand-held Controller Fig 4.5 MOB, Joystick, Hand-held Controller Connections...
  • Page 88 H-Range Pilot User Manual Part 4 - Installation Information 4.2.4 Hydraulic Ram Drive Connections DRIVE DRIVE SUPPLY SUPPLY Heavy Duty Power Supply Rudder Reference Unit Circuit Breaker RRF-ACP Solenoid Connector Hydraulic Ram Drive RAM-T0-12V RAM-T1-12V RAM-T2-12V RAM-T2-24V RAM-T3-24V Fig 4.6 Hydraulic Ram Drive Connections...
  • Page 89 H-Range Pilot User Manual Part 4 - Installation Information 4.2.5 Continuous Drive Connections These are general wiring instructions only, showing the implementation of the ACP outputs to drive a continuous drive pump solenoid valves. The continuous drive pump motor will also require a heavy-duty supply, which is not provided.
  • Page 90 H-Range Pilot User Manual Part 4 - Installation Information 4.2.6 Direct Speed Input Connections DRIVE DRIVE SUPPLY SUPPLY Consult your dealer for the specific speed sensor and housing type suitable for your vessel Fig 4.8 Direct Speed Input Connections HB-0842-02...
  • Page 91 H-Range Pilot User Manual Part 4 - Installation Information 4.2.7 Linear Feedback Connections DRIVE DRIVE SUPPLY SUPPLY Heavy Duty Power Supply Black Circuit Breaker Solenoid Connector Linear Rudder Reference Unit SEN-RUD-LFB Hydraulic Ram Drive RAM-T1-12V, RAM-T2-12V, RAM-T2-24V, RAM-T3-24V Fig 4.9 Linear Feedback Connections...
  • Page 92 H-Range Pilot User Manual Part 4 - Installation Information 4.2.8 Gyro Stabilised Compass Connections - + - DRIVE DRIVE SUPPLY SUPPLY Cut Back Unused Wires + Red 12V Gyro Compass Supply - Blue Gyro Stabilised Compass Sensor Fig 4.10 Gyro Stabilised Compass Connections...
  • Page 93 H-Range Pilot User Manual Part 4 - Installation Information 4.2.9 Furuno AD10 Connections - + - DRIVE DRIVE SUPPLY SUPPLY Cut Back Unused Wires Furuno AD10 Cable Furuno AD10 Compatible Display Fig 4.11 Furuno AD10 Connections HB-0842-02 4-16...
  • Page 94 H-Range Pilot User Manual Part 4 - Installation Information ROTARY RUDDER REFERENCE SENSOR (RRF) 4.3.1 Installation of RRF A number of key points must be considered for optimum performance of the unit: Mount the unit on a flat surface next to the tiller arm or steering quadrant.
  • Page 95 H-Range Pilot User Manual Part 4 - Installation Information Fig 4.12 Plan View - Typical System with Tiller Arm and Quadrant The RRF can be mounted in many different positions and orientations depending on the layout of the steering system.
  • Page 96 H-Range Pilot User Manual Part 4 - Installation Information If the maximum rudder angle is less than 90º then the position of the RRF or the drag-link must be adjusted so that the operating arm of the RRF swings through a minimum of 90º and the output voltage difference is greater than 1 volt from port to starboard lock.
  • Page 97 H-Range Pilot User Manual Part 4 - Installation Information LINEAR FEED BACK UNIT 4.1.4 Linear Feedback Unit Where installation of the conventional rudder reference unit is difficult or physically impossible, a linear feedback unit (SEN-RUD- LFB) can be used. The linear feedback unit comprises of a tube approximately 23mm (7/8 inch) in diameter and 300mm (12 inch) long.
  • Page 98 H-Range Pilot User Manual Part 4 - Installation Information RUDDER DRIVE UNIT 4.5.1 Description A compact dc driven reversible hydraulic pump cylinder assembly for boats without hydraulic steering systems. Three sizes of ram are available giving a wide thrust range to suit all sizes and types of vessel.
  • Page 99 H-Range Pilot User Manual Part 4 - Installation Information 4.5.2 Sterndrive Unit Connections DRIVE DRIVE SUPPLY SUPPLY Heavy Duty Power Supply (12 v Only) BLACK Rudder Reference Unit Stern Drive Unit (Power Assisted) Fig 4.17 Sterndrive Unit Connections HB-0842-02 4-22...
  • Page 100 H-Range Pilot User Manual Part 4 - Installation Information 4.5.3 12V/24V Rotary Drive Connections DRIVE DRIVE SUPPLY SUPPLY Heavy Duty Power Supply BLACK Rudder Reference Unit Note: 12V Unit, 12V Power Supply 24V Unit, 24V Power Supply Rotary Drive Unit (12V or 24V) Fig 4.18 12V/24V Rotary Drive Connections...
  • Page 101 H-Range Pilot User Manual Part 4 - Installation Information 4.5.4 Proportional Solenoid Connections These are general wiring instructions only, showing the connection of the ACP Computer Unit outputs to drive proportional solenoid valves. The continuous drive pump motor will also require a heavy- duty supply;...
  • Page 102 H-Range Pilot User Manual Part 4 - Installation Information USING A NON-B&G SPEED SENSOR The speed sensor must have a speed signal output from a Hall- effect device giving positive pulses up to a maximum of 12V. (1) Locate the cable from the speed sensor to the instrument input.
  • Page 103 H-Range Pilot User Manual Part 4 - Installation Information Pilot Computer Function Cable Unit Boatspeed 135-0B-098 Terminals [ts3] GREEN Speed Signal Input Red Wire Not Used Not Used BLACK Ground Blue Wire SILVER Screen Screen Table 4.5 Non-B&G Paddle Connection...
  • Page 104 H-Range Pilot User Manual Part 5 - Options PART 5 - OPTIONS CONTENTS Para Page ADVANCED CONTROL PROCESSOR UNIT RUDDER DRIVE OPTIONS 5.2.1 Ram Drives 5.2.2 Ram Drive Unit Installation 5-10 5.2.3 Mounting a Blue Ram on a vertical Bulkhead 5-14 5.2.4...
  • Page 105 H-Range Pilot User Manual Part 5 - Options CONTENTS (Contd) TABLES Table No Page Ram Drive Units Ram Drive Technical Data Hydraulic Drive Pump Data 5-15 Outdrive Drive Unit Data 5-20 Mounting Bracket Kits 5-20 Rotary Drive Data 5-22 HB-0842-02...
  • Page 106 H-Range Pilot User Manual Part 5 - Options PART 5 - OPTIONS ADVANCED CONTROL PROCESSOR UNIT The Advanced Control Processor (ACP) Unit contains all the electronics for the Autopilot operation and control of the rudder drive options. It is designed to be mounted on a vertical flat, smooth surface.
  • Page 107 H-Range Pilot User Manual Part 5 - Options RUDDER DRIVE OPTIONS 5.2.1 Ram Drives A compact DC driven reversible hydraulic pump and hydraulic cylinder assembly for boats without hydraulic steering systems. Three sizes of ram drive are available giving a wide thrust range to suit all sizes and types of vessel.
  • Page 108 H-Range Pilot User Manual Part 5 - Options The following table may be used to determine the steering system geometry for different maximum rudder angles and ram type. The last three columns show the peak torque available (in Kgm), amidships position and at maximum rudder angle, with the latter two having the motor running at 50% duty cycle.
  • Page 109 H-Range Pilot User Manual Part 5 - Options RAM - T2-12V Midstroke ACP2 d=73.3 mm = 505 mm only 1/2 max Tiller Offset Thrust Torque Torque at Torque Rudder (peak midships Angle Kgf) midships max º (peak Kgm) Kgm) RAM - T3-24V...
  • Page 110 H-Range Pilot User Manual Part 5 - Options Fig 5.1 Ram Drive Unit Dimensions - Blue Size 1 & 2 HB-0842-02...
  • Page 111 H-Range Pilot User Manual Part 5 - Options Fig 5.2 Ram Drive Unit Dimensions - Blue Size 3 HB-0842-02...
  • Page 112 H-Range Pilot User Manual Part 5 - Options Fig 5.3 Rose Joint and Ram Bolt Detail HB-0842-02...
  • Page 113 H-Range Pilot User Manual Part 5 - Options 5.2.2 Ram Drive Unit Installation General consideration must be given to the steering system and its geometry before commencement of the installation. Many factors must be contemplated for a practical solution. The information given here is for guidance only, although where a maximum or minimum value is given this must be adhered to.
  • Page 114 H-Range Pilot User Manual Part 5 - Options The reservoir tap has been switched to the ON position allowing the oil to flow between the reservoir and the pipe. Note The tap ON position is in alignment with the pipe.
  • Page 115 H-Range Pilot User Manual Part 5 - Options Fig 5.5 Ram Mounted Parallel to Vessel’s Centre-line KEY POINTS ON INSTALLATION Ensure that the rudder angle is limited by the rudder stops and not the limit of travel of the ram arm. Failure to do this will damage the unit and invalidate the warranty.
  • Page 116 H-Range Pilot User Manual Part 5 - Options b= tiller arm a=half max rudder angle Fig 5.6 Vertical Bulkhead Installation HB-0842-02 5-13...
  • Page 117 H-Range Pilot User Manual Part 5 - Options 5.2.3 Mounting a Blue Ram on a Vertical Bulkhead Due to the restricted movement of the ram of +14 , -10 for the size 0, 1 and 2 and +/- 5 for the size 3, it is important that the...
  • Page 118 H-Range Pilot User Manual Part 5 - Options 5.2.5 Hydraulic Drive Pumps The Reversible Hydraulic Drive Pump has a small high speed pump driven by a 12V or 24V DC permanent magnet motor. The pump has pilot check valves to prevent back driving and a pilot operated reservoir valve to enable the unit to drive balanced or unbalanced cylinders.
  • Page 119 H-Range Pilot User Manual Part 5 - Options 105mm (4.13) 4 holes 7.0mm (0.28) 80mm (3.15) 240 mm (9.45) 88.9mm 50.8mm (3.5) (2.00) centres centres Fig 5.7 Type 1 and 2 Hydraulic Pump Dimensions Fig 5.8 Type 3 Hydraulic Pump Dimensions...
  • Page 120 H-Range Pilot User Manual Part 5 - Options 5.2.6 Hydraulic Drive Pump Installation Important Note When dealing with any hydraulic system great care must be taken to ensure that a high degree of cleanliness is observed and no dirt, moisture or foreign objects are allowed to enter the system. Only the recommended fluids must be used.
  • Page 121 H-Range Pilot User Manual Part 5 - Options (12) Check the fluid level in the helm unit reservoir. (13) When the system appears to be fully functional, with the pump running and the helm hard over check for leaks. (14) Secure all hoses and cables to prevent damage.
  • Page 122 H-Range Pilot User Manual Part 5 - Options Fig 5.11 Dual Station System with Bypass Example Fig 5.12 Dual Station Pressurised System Example HB-0842-02 5-19...
  • Page 123 H-Range Pilot User Manual Part 5 - Options 5.2.7 Outdrive Drive Unit Description A compact reversible 12V DC hydraulic pump/reservoir unit with actuating cylinder for autopilot control of outdrive power-assisted hydraulic steering systems. Mounting brackets for attaching the cylinder to the power steer unit depends upon engine type and are listed below.
  • Page 124 H-Range Pilot User Manual Part 5 - Options Fig 5.13 Outdrive Drive Unit - Dimensions 5.2.8 Rotary Drive Unit Description A compact reversible 12V or 24V DC motor and gearbox, with an electrically operated clutch acting on the output shaft for autopilot control of mechanical steering systems.
  • Page 125 H-Range Pilot User Manual Part 5 - Options Supply Voltage 12V or 24V Options Peak Output Torque Type 1 15 Nm/132lb ins Peak Output Torque Type 2 45 Nm/398lb ins Maximum Shaft Speed 20 rpm Typical Power Consumption 3 to 7 amps...
  • Page 126 H-Range Pilot User Manual Part 5 - Options Fig 5.15 Rotary Drive Unit Dimensions HB-0842-02 5-23...
  • Page 127 H-Range Pilot User Manual Part 5 - Options 5.2.9 Rotary Drive Sprocket Wheel Selection The number of teeth on the drive sprocket wheel must be chosen to match each installation. The following guide may be used to select an appropriate sprocket. The aim is to achieve a hard-over to hard-over time of 10 to 12 seconds.
  • Page 128 H-Range Pilot User Manual Part 6 - Diagnostic Data PART 6 - DIAGNOSTIC DATA CONTENTS Para Page DIAGNOSTIC DATA INTRODUCTION 6.1.1 Error Messages FAULT DIAGNOSIS 6.2.1 Fault 100 - Uncommissioned 6.2.2 Fault 101 - Halcyon Gyro Stabilised Compass 6.2.3 Fault 102 - Rudder Reference 6.2.4...
  • Page 129 H-Range Pilot User Manual Part 6 - Diagnostic Data Intentionally Left Blank HB-0842-02...
  • Page 130 H-Range Pilot User Manual Part 6 - Diagnostic Data PART 6 - DIAGNOSTIC DATA DIAGNOSTIC DATA INTRODUCTION The Pilot Computer is continually monitoring the Pilot and Hydra/Hercules System for correct operation. If an error is detected the Pilot Display will show an error message. When an error occurs, the system audible alarm will sound.

  • Page 131: Compass Data

    H-Range Pilot User Manual Part 6 - Diagnostic Data Fault Cause Fault Description The boat is stationary or the No Boat Speed speed sensor has stopped FAULT 104 transmitting data Compass data from Halcyon External Compass 2000 via Instrument System...
  • Page 132 H-Range Pilot User Manual Part 6 - Diagnostic Data No regular messages being received by Pilot FFD from Pilot Computer via instrument system NO PILOT Pilot Display Unit network, i.e. either the display is not receiving or the Pilot computer is not transmitting.

  • Page 133: Fault Diagnosis

    H-Range Pilot User Manual Part 6 - Diagnostic Data FAULT DIAGNOSIS 6.2.1 Fault 100 - Uncommissioned Fault Description Rudder not commissioned or memory has been corrupted. Remedy (1) Has rudder ever been successfully commissioned? Yes - go to 4. - go to 2.

  • Page 134: Fault 101 - Halcyon Gyro Stabilised Compass

    H-Range Pilot User Manual Part 6 - Diagnostic Data 6.2.2 Fault 101 – Halcyon Gyro Stabilised Compass Fault Description The signal from the Pilot compass is too big or too small. Remedy (1) Check for magnetic interference near compass position.

  • Page 135: Fault 103 - Rudder Drive

    H-Range Pilot User Manual Part 6 - Diagnostic Data reference unit. Note the difference between the signal voltages measured at the two end stops must be at least 1.0 volt. (3) Set display (Hydra or Hercules) to show digital rudder angle in degrees. Move helm to Port and Starboard end stops;...
  • Page 136 H-Range Pilot User Manual Part 6 - Diagnostic Data (3) Move the helm. Does the rudder indicator work, if not, check installation of rudder reference unit as detailed above. (4) Select "Power Steer" mode. If drive system includes a clutch or solenoid valve, engage the pilot and check the operation of the clutch or solenoid valve.

  • Page 137: Fault 104 - No Boat Speed

    H-Range Pilot User Manual Part 6 - Diagnostic Data 6.2.5 Fault 104 - No Boat Speed Fault Description The boat is stationary or the speed sensor is not working. Remedy (1) If boat speed for pilot comes from instrument system, check speed shown on instrument system display.

  • Page 138: Fault 108 - Bad Nmea Data

    H-Range Pilot User Manual Part 6 - Diagnostic Data (3) Check operation of Position Fixer. Has NMEA output been selected and enabled? Has autopilot output been enabled? Refer to the Position Fixer Manual. 6.2.8 Fault 108 - Bad NMEA Data...

  • Page 139: Fault 111 - Current Trip

    H-Range Pilot User Manual Part 6 - Diagnostic Data (2) Check operation other Hercules 2000 Performance unit functions. 6.2.11 Fault 111 - Current Trip Fault Description The current limit circuit for the drive motor (25 Amps ACP1 or 40 Amps ACP2) or the clutch (2 Amps) has tripped.
  • Page 140 H-Range Pilot User Manual Part 6 - Diagnostic Data 6.2.13 Fault 113 – Memory Card Changed Fault Description The memory card fitted is from another pilot and the rudder end-stops are no longer valid. All other information will remain intact.
  • Page 141 H-Range Pilot User Manual Part 6 - Diagnostic Data 6.2.16 Pilot Display Shows "No Pilot" Fault Description No regular messages being received by Pilot FFD from Pilot Computer via instrument system network, i.e. either the display is not receiving or the Pilot computer is not transmitting.
  • Page 142 H-Range Pilot User Manual Part 6 - Diagnostic Data PILOT DOES NOT STEER IN A STRAIGHT LINE Fault Description The Pilot seems unable to steer straight, it continually overcorrects course errors; the wake has an "S" like appearance as the boat first steers several degrees off course to Port followed by several degrees off course to Starboard.
  • Page 143 H-Range Pilot User Manual Part 6 - Diagnostic Data Intentionally Left Blank HB-0842-02 6-16...

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