ST80 Active Wind Transducer

Z219

D2720-1

Z219 ST80 Active Wind Transducer Service Procedures

ST80 Active Wind Service Procedures 83067-1 1

 ST80 Active Wind Transducer

CE MARKING OF EQUIPMENT/REPLACEMENT PARTS

WARNING
If the Autohelm equipment under repair, test, calibration, installation or
setting to work carries the European CE mark, only parts and compo-
nents supplied or approved for such use by Autohelm should be used in
order to maintain compliance with the relevant CE requirements.
Incorporation, use or attachment, by any means, of parts or components
not supplied for or not approved for such use by Autohelm or, if supplied
or approved for use by Autohelm, not properly fitted in accordance with
instructions published, provided or recommended by Autohelm, may
cause the equipment to malfunction and, in particular, to become unsafe
Z219

or to no longer meet the relevant CE requirements. In these circum-

stances, Raytheon Marine Europe Ltd excludes liability to the fullest extent
permissible in law for any loss or damage including any liability for its
contribution to such loss or damage by its negligent acts or omissions .

2 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

Contents
1. Description .................................................................... 5
2. Operation ...................................................................... 5
3. Disassembly ................................................................... 6
4. Assembly ....................................................................... 7
5. Functional Test ............................................................... 9
5.1 Preliminary Inspection ........................................................ 9
5.2 Test Equipment .................................................................. 9
5.3 Functional Test Flowchart ................................................. 10
6. Spares Numbers .......................................................... 11

Z219
7. Circuit Description ....................................................... 12
7.1 Power Supplies ................................................................ 12
7.2 External Signals ............................................................... 13
SeaTalk ............................................................................... 13
Anemometer ....................................................................... 13
Wind Vane ........................................................................... 13
Connector Signals (Main PCB) .............................................. 14
SeaTalk Cable ................................................................... 14
PL1 (Wind Vane) ................................................................ 14
PL2 (Anemometer) ............................................................ 14
7.3 Signal Processing ............................................................ 15
Microprocessor................................................................... 15
Autohelm ASIC .................................................................... 15
8. PCB Details .................................................................. 17
8.1 PCB Layout ..................................................................... 17
8.2 PCB Component Lists ...................................................... 19
Anemometer PCB, Components......................................... 19
Vane PCB, Components..................................................... 19
Main PCB, Surface Mount Components, component side .... 19
Main PCB, Conventional Components, component side ....... 19

ST80 Active Wind Service Procedures 83067-1 3

 ST80 Active Wind Transducer

Main PCB, Surface Mount Components, underside .............. 19

Main PCB, Conventional Components, underside ................. 20

Illustrations

Figure 1 Exploded View ............................................................... 8

Figure 2 Test Equipment Connection............................................ 9
Figure 3 Block Diagram ............................................................ 16
Figure 4 Component Layout ...................................................... 17
Figure 5 Circuit Diagram ........................................................... 18
Z219

4 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

1. Description
This section of the Maintenance Manual covers the servicing procedures
for the ST80 Active Wind Transducer, Product Code Z219.
The transducer measures wind speed and direction using an anemometer
cup assembly and a wind vane, each mounted on independent shafts at
either end of a pod containing electronic circuitry.
Electronic signals generated by an opto - electric integrated circuit and a
mechanical interrupter coupled to a shaft on which a cup assembly ro-
tates. When the cups are driven by the wind the generated signals are
converted into data representing wind speed.
The wind vane rotates on a shaft to which a magnet is attached. Hall effect
integrated circuits detect the position of the magnet in two orthagonal
axes, and the output signals of the circuits are converted to data repre-

Z219
senting the position of the wind vane.
Position and speed data are broadcast on the SeaTalk bus at one - second
intervals, thus becoming available to other elements of the system.
Parameters defining upper and lower limits of wind speed and angle, both
true and apparent, can be entered (through other elements of the system)
to cause alarms to be generated when a specified limit is exceeded.
Alarms are also broadcast on the SeaTalk bus at intervals of one second
while the alarm condition exists.

2. Operation
There are no operational activities required to prepare the Active Wind
Transducer for servicing.

ST80 Active Wind Service Procedures 83067-1 5

 ST80 Active Wind Transducer

3. Disassembly
Refer to Figure 1, Exploded View.
When handling any of the PCBs, linen or other suitable material (not nylon)
gloves should be worn if an anti - static mat and grounding strap are not
used. If gloves are not available, handle the PCB by the edges only.
1. Release the grub screws (12) holding the wind vane (1) and anemom-
eter cup assemblies (11). Back the screws just enough to free the
assemblies without allowing the nuts (4) to fall out. Remove the vane
and cup assemblies
2. Pull the anemometer head (10) out of the main body (8) and unplug the
ribbon cable (5) from PL1. To release the cable, lift the top bar of the
connector and slip the cable free (see detail in Figure 1)
3. Pull the wind vane head (2) out of the main body (8) and unplug the
Z219

ribbon cable (5) from PL1. To release the cable, lift the top bar of the
connector and slip the cable free (See detail in Figure 1)
4. Slide the PCB (7) out of the main body through the top (wind vane end)
5. To release the PCB, unsolder the SeaTalk cable (6) from the contact
pads (see detail on Figure 1).

6 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

4. Assembly
Refer to Figure 1, Exploded View.
When handling any of the PCBs, linen or other suitable material (not nylon)
gloves should be worn if an anti - static mat and grounding strap are not
used. If gloves are not available, handle the PCB by the edges only.
1. Solder the SeaTalk cable (6) to the main PCB (7) contact pads (see
detail, Figure 1 for cable colours and connections)
2. Lift the top bars of main PCB connectors PL1 and PL2 and insert the
ribbon cables (5). Press the bars down to secure the cables (see detail
in Figure 1). For both connectors on the PCB, the coloured side of the
cable faces the centre of the PCB
3. Slide the PCB into the main body (8) from the top (wind vane end),
threading the lower ribbon cable through as the PCB enters. The PCB

Z219
is tapered and fits narrow end first
4. Check that the O - rings (3) on the anemometer (10) and wind vane (2)
heads are not damaged, distorted or loose and are free of grease and
dirt. Replace or clean as necessary
5. Plug the lower ribbon cable (5) into PL1 of the anemometer PCB (9)
(see detail in Figure 1), ensuring that the cable is not twisted. The
coloured side of the cable faces the outer edge of the board
6. Push the anemometer head (10) into the main body (8), ensuring that
the head is fully home and the ribbon cable (5) is not twisted
7. Plug the lower ribbon cable (5) into PL1 of the wind vane PCB (4) (see
detail in Figure 1), ensuring that the cable is not twisted. The coloured
side of the cable faces the outer edge of the board
8. Push the wind vane head (2) into the main body, ensuring that the head
is fully home and the ribbon cable (5) is not twisted
9. Fit the cup assembly (11) to the lower shaft and the wind vane (1) to the
upper shaft. Insert and tighten the grub screws (12). Check that the
vane and cups rotate freely in both directions.

ST80 Active Wind Service Procedures 83067-1 7

 ST80 Active Wind Transducer

11

PL1

5
Z219

Red
PL1 Screen

PL2 Yellow

5
6

Ribbon connector detail 8

Open
position

Closed 1. Wind vane

position 2. Wind vane head
3. 'O' ring (2 off)
4. Nut
5. Ribbon cable
6. SeaTalk cable
7. Main PCB
PL1 8. Body
9. Anemometer head
9 10. Cup assembly
3

10

11
D2711-1

Figure 1 Exploded View

8 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

5. Functional Test

5.1 Preliminary Inspection

Before testing, inspect the equipment for physical damage (cracked or
broken case, bent/corroded/burnt connector pins, etc.). Clean off any
grease, dirt or deposits in or on the equipment.
Check for signs of water ingress. Check for damage to the pod PCB, in
particular, overheating on the power supply input pins and PCB tracks.

5.2 Test Equipment

Z219
3 4 1 5 2 6

1. Known good ST80 wind head

2. Daisychain cable
3. Power cable
4. 5A Fuse/circuit breaker
+ + 5. 12V 5A power supply
6. ST80 Active wind
transducer under test

D2712-1

Figure 2 Test Equipment Connection

ST80 Active Wind Service Procedures 83067-1 9

 ST80 Active Wind Transducer

5.3 Functional Test Flowchart

CONNECT POWER AND SWITCH ON.
SET APPARENT WIND SPEED

CHECK DISPLAY SHOWS ZERO

SPEED, NOT BLANK OR DASHES
app

00.0
KTS

N CHECK CONNECTING
OK CABLES
Y
Y
OK CHANGE PCB
& RESTART
N
CORRECT FAULT
& RESTART

ROTATE ANEMOMETER, CHECK

LCD RESPONDS BY INDICATING
A WIND SPEED

N CHECK CONNECTING
OK CABLES
Z219

Y
Y CHANGE PCB
OK
& RESTART
N
CORRECT FAULT
& RESTART

ROTATE WINDVANE, CHECK

INSTUMENT POINTER FOLLOWS
VANE MOVEMENTS

N CHECK CONNECTING
OK
CABLES & RETRY
Y
Y CHANGE PCB
OK
& RESTART
N

CORRECT FAULT
& RESTART

POWER OFF; END OF TEST

10 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

6. Spares Numbers
Item Cat. No. Part No. Comments
30m Extension D252
Cable
50m Extension D253
Cable
Anemometer Pod Q140 9
Sub-Assembly
Vane Pod Q141 2
Sub-Assembly
PCB Sub-Assembly Q142 7

Z219
Anemometer W062 10
Vane W063 1
Arm Sub-Assembly W064 8

ST80 Active Wind Service Procedures 83067-1 11

 ST80 Active Wind Transducer

7. Circuit Description
Refer to Figure 3, Block Diagram and Figure 5, Circuit Diagram.
Two sensor PCBs (round boards) feed the main PCB. Interconnection and
elements on the round boards are shown in the bottom right corner of
the block diagram.
One sensor (anemometer) detects rotation of the wind cups and produces
a pulse train which is used to calculate the wind speed. The other sensor
(wind vane) detects the rotation of a magnet attached to the wind vane
shaft from which the wind angle is calculated.
The main PCB processes signals from the sensors and interprets mes-
sages from other system elements. SeaTalk sentences containing wind
speed, wind angle and alarm conditions are generated for transmission on
the SeaTalk bus.
Z219

7.1 Power Supplies

A nominal 12V supply enters the unit via the red lead of the SeaTalk cable.
Varistor V1 placed across the supply and 0V (black lead of the SeaTalk
cable) provides protection against power surges and voltage spikes.
Diode D1, similarly placed across the supply and 0V, provides limited
protection against lightning strikes.
The input supply is routed as follows:
1. Through reverse protection diode D4 to IC1, a regulator which pro-
vides +5V (Vcc) to the circuitry on the PCB. The output of diode D4
(nominally 12V) is sent through diode D6 to ASIC IC5, as signal VHELD
2. Through diode D3 as signal 12V to regulator IC2 (or alternative fit 8V
regulator IC9).

Regulator IC2 (or alternative fit 8V regulator IC9) provide an 8V supply to

digital - to - analogue convertor IC8. The sensor PCBs (wind vane and
anemometer) are supplied with 8V through PL1 and PL2.
Reverse diode D5 ensures a floating 0V for the circuitry by isolating the
incoming 0V.

12 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

7.2 External Signals

SeaTalk
SeaTalk signals carried by the yellow lead of the SeaTalk cable are routed
directly to the Autohelm ASIC IC5.
Diode D2 placed across the data line and 0V provides limited protection
against lightning strikes.
Incoming signals are converted by the ASIC from SeaTalk duplex line
format to SeaTalk DATA IN format for the microprocessor.
Outgoing signals from the microprocessor are converted from SeaTalk
DATA OUT format at CMOS voltage levels to SeaTalk format at 12V level by
the ASIC.

Z219
Anemometer
Pulses are generated by opto - electric integrated circuit IC3, at a rate
dependent on wind speed, by the action of an opto - interrupter on the cup
mounting shaft at the lower end of the assembly.
The output of IC3 is fed via PL1 (round board) and PL2 (main PCB) to
comparator IC3a which uses the reference voltage produced by resistors
R8 and R9 to provide a clean input to microprocessor IC7.

Wind Vane
Hall effect sensors IC1 and IC2 on the round board at the top end of the
assembly detect the position of a magnet mounted on the wind vane shaft.
The resulting analogue voltages (sine and cosine, representing orthagonal
two - axis sensing) are fed via PL1 (round board) and PL1 (main PCB) to
comparators IC3b and IC3d.
The microprocessor sets up bits 1 to 10 on the input of digital - to - ana-
logue convertor IC8, which produces a reference voltage at the output
(VREF). VREF is fed via IC4a to comparators IC3c (cosine), IC3b (sine) and
IC3d (VTEST).
When the reference voltage and the inputs from the Hall Effect sensors
are matched, the outputs of the comparators change state and, as the
microprocessor knows the digit pattern set up to cause this change, the
position of the magnet in relation to the sensors can be calculated.
A test signal (VTEST) is produced by comparator IC3d.

ST80 Active Wind Service Procedures 83067-1 13

 ST80 Active Wind Transducer

7. Circuit Description
Refer to Figure 3, Block Diagram and Figure 5, Circuit Diagram.
Two sensor PCBs (round boards) feed the main PCB. Interconnection and
elements on the round boards are shown in the bottom right corner of
the block diagram.
One sensor (anemometer) detects rotation of the wind cups and produces
a pulse train which is used to calculate the wind speed. The other sensor
(wind vane) detects the rotation of a magnet attached to the wind vane
shaft from which the wind angle is calculated.
The main PCB processes signals from the sensors and interprets mes-
sages from other system elements. SeaTalk sentences containing wind
speed, wind angle and alarm conditions are generated for transmission on
the SeaTalk bus.
Z219

7.1 Power Supplies

A nominal 12V supply enters the unit via the red lead of the SeaTalk cable.
Varistor V1 placed across the supply and 0V (black lead of the SeaTalk
cable) provides protection against power surges and voltage spikes.
Diode D1, similarly placed across the supply and 0V, provides limited
protection against lightning strikes.
The input supply is routed as follows:
1. Through reverse protection diode D4 to IC1, a regulator which pro-
vides +5V (Vcc) to the circuitry on the PCB. The output of diode D4
(nominally 12V) is sent through diode D6 to ASIC IC5, as signal VHELD
2. Through diode D3 as signal 12V to regulator IC2 (or alternative fit 8V
regulator IC9).

Regulator IC2 (or alternative fit 8V regulator IC9) provide an 8V supply to

digital - to - analogue convertor IC8. The sensor PCBs (wind vane and
anemometer) are supplied with 8V through PL1 and PL2.
Reverse diode D5 ensures a floating 0V for the circuitry by isolating the
incoming 0V.

14 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

7.2 External Signals

SeaTalk
SeaTalk signals carried by the yellow lead of the SeaTalk cable are routed
directly to the Autohelm ASIC IC5.
Diode D2 placed across the data line and 0V provides limited protection
against lightning strikes.
Incoming signals are converted by the ASIC from SeaTalk duplex line
format to SeaTalk DATA IN format for the microprocessor.
Outgoing signals from the microprocessor are converted from SeaTalk
DATA OUT format at CMOS voltage levels to SeaTalk format at 12V level by
the ASIC.

Z219
Anemometer
Pulses are generated by opto - electric integrated circuit IC3, at a rate
dependent on wind speed, by the action of an opto - interrupter on the cup
mounting shaft at the lower end of the assembly.
The output of IC3 is fed via PL1 (round board) and PL2 (main PCB) to
comparator IC3a which uses the reference voltage produced by resistors
R8 and R9 to provide a clean input to microprocessor IC7.

Wind Vane
Hall effect sensors IC1 and IC2 on the round board at the top end of the
assembly detect the position of a magnet mounted on the wind vane shaft.
The resulting analogue voltages (sine and cosine, representing orthagonal
two - axis sensing) are fed via PL1 (round board) and PL1 (main PCB) to
comparators IC3b and IC3d.
The microprocessor sets up bits 1 to 10 on the input of digital - to - ana-
logue convertor IC8, which produces a reference voltage at the output
(VREF). VREF is fed via IC4a to comparators IC3c (cosine), IC3b (sine) and
IC3d (VTEST).
When the reference voltage and the inputs from the Hall Effect sensors
are matched, the outputs of the comparators change state and, as the
microprocessor knows the digit pattern set up to cause this change, the
position of the magnet in relation to the sensors can be calculated.
A test signal (VTEST) is produced by comparator IC3d.

ST80 Active Wind Service Procedures 83067-1 15

 ST80 Active Wind Transducer

MAIN PCB 12V

D3

+12V RED 12V HELD

D4 D6

(V1) D1 REGULATOR IC1 +5V

0V BLACK 0V
D2 D5
SeaTalk 12V
SeaTalk DATA IN
DATA YELLOW P3.1 IC2
SeaTalk 0V
SeaTalk DATA OUT REGULATOR +8V
CABLE P3.0
12V
RESET (IC9)
RESET RST
IC5 0V
W'DOG REGULATOR
W'DOG P1.4 (ALTERNATIVE FIT)
R-C TIMING
COMPONENTS
12V
POWER FAIL
12V HELD P3.5
Z219

ASIC

SCL P1.1
IC6
SDA P3.3
EEPROM

XTAL REF TO IC3a, IC3d

XL1
+5V

12MHz R8
CRYSTAL +
REF IC7 OUT1
R9
PL2 IC4b
1
0V 0V OUT2
2 0V
8V 8V
3
NC +
a P3.2 P3.7 (MSB) BIT1
4
ANEMOMETER
OUTPUT P3.6 BIT2
IC8
P2.7 BIT3
IC3 +
BIT4 VREF
P2.6
PL1 0V
P2.5 BIT5 R11 IC4a
+
1 d VTEST BIT6
8V 8V P3.4 P2.4 R10

P2.3 BIT7
SINE 2 +
b SINE BIT8
P1.5 P2.2

P2.1 BIT9
COSINE 3 +
c COSINE (LSB) BIT10
P1.0 P2.0

0V 4 0V
COMPARATORS MICROPROCESSOR D/A CONVERTOR

ROUND PCBS SeaTalk BUS

PL1 PL1
0V
8V PL1 PL2 PL1 PL1
8V RED BLACK YELLOW
R2 +12V 0V SeaTalk
SINE IC1 SOLDERED CONNECTIONS IC1
IC3
O/P IC3
IC2
COSINE IC2
R1
0V ANEMOMETER MAIN PCB WIND VANE
ANEMOMETER WIND VANE PCB INTERCONNECTION D2713-1

Figure 3 Block Diagram

Signal flow is left to right except where indicated

16 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

8. PCB Details

8.1 PCB Layout

Anemometer PCB Main PCB

Surface Mount Conventional

Components, Components,
Component Side componet side componet side

Underside

Z219
Taken from Drawing No: 4288-009
Issue: E Date: 07.02.96

Surface Mount Conventional

Vane PCB Components, Components,
underside underside

Component Side

Underside

Taken from Drawing No: 4288-011

Issue: C Date: 01.02.96 Taken from Drawing No: 4288-007 Issue: L Date: 10.09.96

D2714-1

Figure 4 Component Layout

ST80 Active Wind Service Procedures 83067-1 17

 ST80 Active Wind Transducer
Z219

D2715-1

Figure 5 Circuit Diagram

18 ST80 Active Wind Service Procedures 83067-1

ST80 Active Wind Transducer

8.2 PCB Component Lists

Anemometer PCB, Components

Taken from Drawing No: 4288-009 Issue: E Date:07.02.96 D3955-1

Vane PCB, Components

Taken from Drawing No: 4288-011 Issue: C Date:07.02.96 D3956-1

Main PCB, Surface Mount Components, component side

Z219
Taken from Drawing No: 4288-007 Issue: L Date:10.09.96 D3957-1

Main PCB, Conventional Components, component side

Taken from Drawing No: 4288-007 Issue: L Date:10.09.96 D3958-1

Main PCB, Surface Mount Components, underside

D3959-1
Taken from Drawing No: 4288-007 Issue: L Date:10.09.96

ST80 Active Wind Service Procedures 83067-1 19

 ST80 Active Wind Transducer

Main PCB, Conventional Components, underside

Taken from Drawing No: 4288-007 Issue: L Date:10.09.96 D3960-1

Z219

20 ST80 Active Wind Service Procedures 83067-1