CONTENTS
1 INTRODUCTION
1.1 Electronics PCBs
1.2 Mechanical Components
2 OPERATION
3 ASSEMBLY INSTRUCTIONS
4 MECHANICAL ASSEMBLY DRAWINGS
4.1 Wheelpilot
Final Assembly WP5000 E01258 (SHT 1 & 2)
Gearbox Assembly E01259
Unit Interconnection Assembly E01268
4.2 Hand Programmer
Assembly: Hand Programmer E01060
Assembly: Case Bottom E01286
Case Top Assembly E01287
Cable Assembly 5 Core E01368
5 CIRCUIT DESCRIPTIONS
5.1 Gearbox PCB
5.2 Control PCB
5.3 Hand Programmer PCB Assembly
6 CIRCUIT DIAGRAMS
6.1 Circuit Schematics
Combined Gearbox and Control PCB E01153
HP5000 Circuit Diagram E00820
6.2 Component Lists and Layouts
WP5000 PCB Assembly E01264
Gearbox PCB Assembly E01261
HP5000 PCB Assembly E00822
7 PROGRAMMING AND CONFIGURATION
8 FAULT FINDING
8.1 Common User Faults
8.2 Common Technical Faults
9 SPARE PARTS DETAIL
10 TECHNICAL NOTES
1 INTRODUCTION TO THE WP5000
The WP5000 is a proven product designed for most types of wheel steered yachts up to 10m (33ft) in length. It operates from a simple 3 key control unit and is fully weatherproofed. Installation is fast and simple. Auto Seastate, Auto Trim and adjustable Gain are standard features together with Quick Release Clutch, Instant Course Correction, Auto Tack, Intelligent Steering and Fluxgate Accuracy.
The HP500 Handprogrammer is an advanced hand controller for use with the Wheelpilot WP5000. It provides many features to enhance and optimise the autopilot performance. These features include programming bearing to waypoint, change course by any amount, course dodge, tacking, off course alarm, man-over-board function plus many programmable parameters. It can also provide correction for the autopilot compass to allow correlation of the heading display to the ship’s compass.
The main components of the Wheelpilot are described below:
1.1 Electronics PCBs
Gearbox PCB Assembly E01261
WP5000 PCB Assembly E01264
1.2 Mechanical Components
Final Assembly WP5000 E01258 (SHT 1 & 2)
Gearbox Assembly E01259
Unit Interconnection Assembly E01268
The main components of the hand programmer are:
1.3 Electronics PCB
Hand Programmer PCB E0082
1.4 Mechanical Components
General Assembly Hand Programmer E01060
2 CALIBRATING AND OPERATING THE WP5000
This Service Manual only contains calibration and operational information for those features of the wheelpilot and hand programmer which are not normally available to the end user. For details of normal calibration and operation please refer to the appropriate user manual.
3 ASSEMBLY INSTRUCTIONS
3.1 Assembly Gearbox. Refer to Drawings Numbered E01258 and
E01259. Into the Case Front E00234 fit the Gear Output Assembly E00236, the 26 Tooth Pulley and Gearbox Cover and secure using M3 x 16 Pan Screw 200200. Fit the snap-on Pulley Cover Cap. Fit the Motor Assembly E00239 into the Gearbox Plate Assembly E00235 using 2 M4 x 6 Pan Screws 200082 together with the 3 PCB Stand Off pieces 200136 secured with 3 M3 x 6 Pan Screws, threads lightly smeared with Loctite Screwlock 260020. Fit 100 Tooth Gear Assembly into the Gearbox Plate Assembly and retain with the Hall Effect Magnet Carrier Assembly E01260. Fit the 50 Tooth Gear Assembly E00238 into the Gearbox Plate Assembly ensuring that the spacer shaft is closest to the bearing i.e. drive gear uppermost. Offer up the Complete plate assembly to the case front ensuring that it fits squarely over the Stand Offs and secure with 3 No. 4 x ½ “ AB Pan Poz Screws. Fit the Gearbox PCB E01261 onto the Stand Offs and secure using 3 No. 4 x ½ AB Pan Screws and connect the motor assembly power lead to PLG 2 on the PCB.
Check that the Nytrile ‘O’ Ring 190017 is properly seated into
the Gearbox Case Back and connect the 6 way connector to PLG3 on the PCB. Locate the Case Back onto the main body of the gearbox and secure using 3 No. 6 x ½ Pan Screws 200005 but do not fully tighten. Insert the Red Beading 180001 into the groove between the Gearbox Bottom and Gearbox Top covers and fully tighten the 3 screws.
3.2 Control Unit. Fit the Gimballed Fluxgate Assembly into the
Controller Case Bottom E01167and secure using 2 No. 4 x ¾ AB Pan Screws. Make the 8 way connector to PLG1 on the Control Unit PCB E01264 and pass the compass lead through the hole in the PCB and plug into PLG3 on the PCB ensuring that the compass leads trail towards the centre of the board. Place an ‘O’ Ring 190009 onto the top of each of the support pillars within the Case Bottom, fit PLG2 with a rubber washer, part of the 8 way connector 170085, and fit the PCB into the housing ensuring that the board seats correctly over the pillars. Retain the PCB using the weatherproof cap 190023 and the nut, also part of the 8 way connector. Ensure that the ‘O’ Ring Seal 190032 is correctly seated in the Control Unit Top Case Assembly E01265 and mate the top and bottom cases together securing with 6 No. 4 x ½” AB Pan Screws.
3.1 General Assembly Hand Programmer
Refer to Drawing No. E01060 and Drawing Number E00822 for the wiring key, terminate the cable, part of the Case Bottom Assembly onto the PCB. Locate the PCB over the screw bosses into the case bottom. Run a bead of silicon sealant (260003) into the case bottom sealing groove, locate the case top and secure with the 6 Screws (200056).
4 MECHANICAL ASSEMBLY DRAWINGS
4.1 Wheelpilot
Final Assembly WP5000 E01258 (SHT 1 & 2)
Gearbox Assembly E01259
Unit Interconnection Assembly E01268
4.2 Hand Programmer
Assembly: Hand Programmer E01060
Assembly: Case Bottom E01286
Case Top Assembly E01287
Cable Assembly 5 Core E01368
5 CIRCUIT DESCRIPTIONS
Introduction. The WP5000 contains 2 separate PCBs, the Gearbox PCB and the Control PCB. However, for clarity, the circuit diagrams for both boards are included on one Drawing No. E01153.
5.1 Gearbox PCB.
Supply and Regulation. The WP5000 is designed to work from a
12 V source +/- 30%. The gearbox PCB operates entirely from the 12V supply without regulation. Protection against reverse polarity is provided by D1 and the Fuse located on the gearbox cover and capacitor C1 acts as a reservoir to hold up the supply voltage and reduce any supply dips.
Motor Drive. Drive signals from the Control PCB are connected to the power MOSFETs TR1 to TR4 which are arranged in an ‘H’ Bridge configuration. In the absence of a control signal pull-up resistors R2 and R3 will cause both TR2 and TR4 to switch ON providing a short circuit path across the motor terminals and hence active braking. Should either of the control lines go high then a voltage will be provided across the motor and cause it to drive. The direction of drive is dependent on which control line is active. Consider PLG2 pin 6 going high; TR2 would switch off, TR1 would switch on and a voltage would be provided across the motor. Should PLG5 pin 2 go high then the same action occurs in the alternative MOSFETs and the polarity of the voltage across the motor is reversed.
The control unit will not allow both drive lines to go high simultaneously but should this inadvertently happen then a fail safe condition results. Both TR1 and TR3 would switch ON and TR2 and TR4 would switch OFF. Thus there would be no voltage across the motor and no current flow through the bridge.
Feedback. Mechanical movement is sensed by 2 Hall Effect devices mounted on the Gearbox PCB Assembly E01261. The devices are triggered by rotating magnets mounted in the Magnet Carrier Assembly to produce quadrature style feedback. The 2 feedback signals are interpreted by the microprocessor to provide an accurate assessment of the direction and amount of movement of the drive.
5.2 Control PCB.
Supply and Regulation. Supply for the Control PCB is routed through the Gearbox PCB and protection against reverse polarity is provided by the same components as the Gearbox PCB, D1 and the Fuse located on the gearbox cover. However, the Control PCB requires a 5V regulated supply to operate the remaining circuitry. Capacitor C17 is used as a reservoir to hold up the supply voltage and reduce any supply dips. Protection against over-voltage spikes is provided by Resistors R1, R49 and Zener Diode ZD1 and Regulator REG1 provides a 5V regulated supply.
Microprocessor. The control key lines on Ports PB1 to PB3 are normally pulled to +5V via resistors R36 to R38 and are “scanned” by the microprocessor to detect if any of the switches have been operated and pulled the line LOW.
Microprocessor Reset. Transistors TR1 and TR2 and Zener Diode ZD2 together with associated components provide a reset LOW pulse of approximately 50mS duration at switch on and whenever a 5v supply failure occurs. When the supply voltage dips, the base of TR1 falls below the voltage on its emitter, set by ZD2. Transistor TR1 is thus turned on which in turn switches TR2 on and clamps the Reset line LOW. Resistor R6 provides a small amount of positive feedback to provide Schmitt Trigger action.
Communication. The Wheelpilot can communicate with a Hand controller HP5000 via a serial data link controlled by the microprocessor. Asynchronous data is received via a dual opto-isolator IC3 which provides multiplexing of signals from a hand programmer and radio navigator.
Non-Volatile Memory (NVM). Integrated Circuit IC7 provides memory for the retention of important data after power down including calibration data for the windvane.
Fluxgate (Compass). Two anti-phase signals are provided from microprocessor Ports PA5 and PA6. These signals are buffered by TR3 and TR4 to provide a higher current drive to the excitation coil of the fluxgate. A reference voltage is provided from the output of IC4a decoupled by C14 and C15. The 2 coils, mounted at right angles, provide output signals proportional to the sine and cosine of the Earth’s magnetic field. These signals are fed via the electronic switch IC2, to 2 dual slope integrating analogue to digital converters IC5 and IC6 plus associated components. The outputs of the comparator IC6 are fed to the microprocessor Ports IRQ\ and TCAP which provide input capture facilities. Accurate timing of the conversion is kept by the microprocessor to provide simultaneous precision analogue to digital conversion of both sine and cosine signals to avoid errors created by multiplexing the inputs.
5.3 Hand Programmer PCB Assembly
The circuit diagram for the PCB is given in Drawing No. E00820.
Supply and Regulation. The HP5000 is designed to work from a 12 V source. Protection against incorrect polarity connection is provided by D4 with protection against over-voltage spikes provided by R1 and ZD1. REG1 and associated smoothing capacitors provide a 5V regulated supply from which the internal circuitry is powered.
Microprocessor and Reset. Transistors TR1 and TR2 together with their associated components provide a reset pulse to the microprocessor IC1 at switch on and whenever a 5v supply failure occurs. The microprocessor, with built in LCD driver, reads the key matrix S1 to S10 directly, gives the relevant commands to the LCD and provides drive signals to the display illumination LP1 – LP4 via TR3 and to the buzzer via TR4. Reference voltages for LCD driving are derived from the resistor network R23 – R26. All system parameters are stored in Non Volatile Memory IC2.
Communication. Integrated Circuit IC3 is configured as a precision oscillator to provide clocking to the microprocessor, Pin 17, and IC4 provides a control pulse, lasting 1.5 bytes of data, to prevent clocking of a start bit. Data is fed into the pilot via a buffer TR7 and the line is against short circuit by Resistor R16. Data from the pilot is buffered by TR6 with the line again protected by R17. The Log pulses can also be fed to the processor via R14 and TR5.
6 CIRCUIT DIAGRAMS
6.1 Circuit Schematics
Combined Gearbox and Control PCB E01153
HP5000 Circuit Diagram E00820
6.2 Component Lists and Layouts
Gearbox PCB Assembly E01261
WP5000 PCB Assembly E01264
HP5000 PCB Assembly E00822
7 PROGRAMMING AND CONFIGURATION
This Service Manual only contains programming and configuration information for those features of the autopilot and hand programmer which are not normally available to the end user. For details of normal programming and configuration please refer to the appropriate user manual.
8 FAULT FINDING
8.1 Common User Faults. Common user faults are included in the
Diagnostics guide included in the user manual.
8.2 Common Technical Faults. None yet identified.
9 SPARE PARTS DETAIL
Specific diagrams for spares packs are not yet available. However, the packs and their contents are detailed below and items can be clearly identified by reference to the Assembly Drawings.
Part Number /Description and Contents
WPPK50
/Control Unit PCB Assembly Pack
E01264 PCB Assembly170085 8 Way Weatherproof Chassis Connector
190023 Weathertight Cap
WPPK51
/Control Unit Case Top Pack
E01265 Control Unit Case Top Assembly190032 ‘O’ Ring
WPPK52
/Control Unit Compass Assembly Pack
E01007 Fluxgate Gimballed Assembly
200137 Screw No. 4 x ¾ AB Pan PozWPPK53
/Control Unit Bottom Case Assembly
E01167 Control Unit Bottom Case
190009 ‘O’ Ring Nitrile200002 Screw No. 4 x ½” Pan Poz
190024 Grommet 10 mm
200025 Cable Tie : Large
WPPK54
/Gearbox Bottom Case Assembly
E00148 Gearbox Case Back
200005 Screw No.6 x ½” Pan Head190037 Cable Grommet
270001 Fuse %A 20mm
180072 Cable 4 Core 16-2-4A Black
190036 Cable Grommet
270000 Fuse Holder 20 mm Panel
200025 Cable Tie Large
180002 Cable 8 Core 7-2-8A Black
170048 6 Way Socket
170013 2 Way Housing
170015 Contact Crimp
180032 2 mm Silicon Sleeve
170100 4 Way Waterproof Plug
170003 8 Way Housing (Left unconnected to
facilitate wiring)
180013 Wire 16 / 0.2 PVC Orange
WPPK55
/Gearbox Unit PCB Assembly
E01261 Gearbox PCB Assembly
200000 Screw M3 x 6 Pan SlotWPPK56
/Motor Assembly
E00239 Motor Unit
200082 Screw M4 x 6 Pan SlotWPPK57
/Gearbox Plate Assembly
E00235 Gearbox Plate
200136 PCB Stand Off 17mm200000 Screw M3 x 6 Pan Slot
WPPK58
/Gear Set
E00236 Gear Output Assembly