C-Plath 4000 Autopilot Operation

JA19-8039
Revision F
NAVIPILOT 4000
Heading Control System
Installation and Operation Manual
Also applicable to the ADG 4000 Autopilot
Copyright 2006 Northrop Grumman Systems Corporation (Sperry Marine)

This documentation contains information proprietary to Northrop Grumman Systems Corporation
(Sperry Marine). Any reproduction, disclosure, or use of this documentation is expressly
prohibited except as Sperry Marine may otherwise agree to in writing.
These commodities, technology, or software were exported from the U.S. in accordance
with Export Administration Regulations. Diversion contrary to U.S. law prohibited.
Northrop Grumman Systems Corporation 15 June 2006

Sperry Marine
1070 Seminole Trail
Charlottesville, VA 22901-2891
(434) 974-2000
www.sperry-marine.com
JA19-8039
Revision F
NAVIPILOT 4000
Heading Control System
Installation and Operation Manual
Also applicable to the ADG 4000 Autopilot
Copyright 2006 Northrop Grumman Systems Corporation (Sperry Marine)

This documentation contains information proprietary to Northrop Grumman Systems Corporation
(Sperry Marine). Any reproduction, disclosure, or use of this documentation is expressly
prohibited except as Sperry Marine may otherwise agree to in writing.
These commodities, technology, or software were exported from the U.S. in accordance
with Export Administration Regulations. Diversion contrary to U.S. law prohibited.
Northrop Grumman Systems Corporation 15 June 2006

Sperry Marine
1070 Seminole Trail
Charlottesville, VA 22901-2891
(434) 974-2000
www.sperry-marine.com
Table of Contents
TABLE OF CONTENTS
Para Page
1 DESCRIPTION
1.1 Introduction ......................................................................................................................... 1-1
1.2 Features ............................................................................................................................. 1-1
1.3 Equipment Description ....................................................................................................... 1-2
1.3.1 Control and Display Unit (CDU) .................................................................................... 1-2
1.3.2 Steering Control Unit (SCU) .......................................................................................... 1-2
1.3.3 NAVINET 4000 Steering Control Network .................................................................... 1-2
1.4 Technical Data ................................................................................................................... 1-6
1.4.1 Vessel Application Rules ............................................................................................... 1-6
1.4.2 Interface Requirements ................................................................................................. 1-8
1.5 Related Publications ........................................................................................................... 1-10
2 OPERATION
2.1 Displays .............................................................................................................................. 2-1
2.2. Power-Up ............................................................................................................................ 2-4
2.3 Steering Control Transfer (Takeover Method) ................................................................... 2-4
2.3.1 NONE ............................................................................................................................ 2-4
2.3.2 CALL UP ........................................................................................................................ 2-5
2.3.3 TAKEOVER ................................................................................................................... 2-5
2.3.3.1 Software Versions R and Later ............................................................................... 2-5
2.3.3.2 Software Versions P and Earlier ............................................................................. 2-6
2.4 Steering Control Override ................................................................................................... 2-7
2.4.1 External Override and Miniwheel Override ................................................................... 2-7
2.4.2 ABS Override ................................................................................................................. 2-8
2.5 Mode Selection ................................................................................................................... 2-8
2.5.1 Software Versions R and Later ..................................................................................... 2-8
2.5.2 Software Version P ........................................................................................................ 2-9
2.5.3 Software Versions N and Earlier .................................................................................... 2-9
2.6 Heading Control ................................................................................................................. 2-10
2.6.1 AUTO Mode ................................................................................................................... 2-10
2.6.2 NAV and TRACK Modes ............................................................................................... 2-11
2.6.2.1 NAV Mode ............................................................................................................... 2-11
2.6.2.2 TRACK Mode .......................................................................................................... 2-14
2.7 Select Heading Reference ................................................................................................. 2-15
2.8 Display Adjustment and Test .............................................................................................. 2-16
2.9 Set Weather Control ........................................................................................................... 2-17
2.9.1 Adaptive Self-Tuning Not Enabled ................................................................................ 2-17
2.9.2 Adaptive Self-Tuning Enabled ....................................................................................... 2-18
2.10 Set Magnetic Variation ....................................................................................................... 2-19
2.11 Set Turn Method.................................................................................................................. 2-20
2.12 Set Value ............................................................................................................................ 2-21
2.12.1 Set Rudder Limit ............................................................................................................ 2-21
2.12.2 Set Rate Order .............................................................................................................. 2-22
2.12.3 Set Radius Order ........................................................................................................... 2-23
2.13 Select Speed Source........................................................................................................... 2-25
2.14 Set Off-Heading Limit ......................................................................................................... 2-26
2.15 Set Heading Difference Limit .............................................................................................. 2-27
2.16 Select Loading .................................................................................................................... 2-28
2.17 Change Display Options ..................................................................................................... 2-29
2.18 Tuning.................................................................................................................................. 2-31
2.18.1 Overview ........................................................................................................................ 2-31
2.18.2 Tuning Controls and Displays ....................................................................................... 2-32
JA19-8039F i
NAVIPILOT 4000
TABLE OF CONTENTS - Continued

Para Page
2.18.2.1 TUNING Display ..................................................................................................... 2-32

2.18.2.2 RUDDER GAIN (RG) and COUNTER RUDDER (CR) Controls ............................ 2-34
2.18.2.3 WEATHER RATIO Control ..................................................................................... 2-35
2.18.3 Tuning Procedures ........................................................................................................ 2-36
2.18.3.1 Before Starting the Tuning ...................................................................................... 2-36
2.18.3.2 Performing the Tuning ............................................................................................ 2-37
2.18.3.3 After Completing the Tuning ................................................................................... 2-41
2.18.4 Resetting the Tuning ..................................................................................................... 2-41
2.19 Viewing and Acknowledging Alarms .................................................................................. 2-42
2.20 Emergency Operation ........................................................................................................ 2-42
3 INSTALLATION AND INITIALIZATION

3.1 Steering Control Unit (SCU) Hardware Configuration ........................................................ 3-1
3.2 Optional Steering I/O PCB Installation and Configuration ................................................. 3-3
3.2.1 Isolated Proportional Output Interface PCB ................................................................... 3-3
3.2.2 Solenoid Interface PCBs ............................................................................................... 3-6
3.2.2.1 DC Solenoid Interface PCB ..................................................................................... 3-8
3.2.2.2 AC Solenoid Interface PCB...................................................................................... 3-12
3.3 NAVINET 4000 Steering Control Network - Bus Configuration ......................................... 3-16
3.4 Software Configuration Parameters ................................................................................... 3-18
3.5 Alarm/Status Relays ........................................................................................................... 3-18
3.6 Connecting to a Voyage Data Recorder (VDR) ................................................................. 3-21
3.7 Connecting to the NAV Channel ........................................................................................ 3-21
3.8 Using An External Input With A Mechanical Mode Switch (MMS) ..................................... 3-21
3.9 Helm Unit Calibration ......................................................................................................... 3-21
3.10 Rudder Repeatback (Feedback) Calibration Or Zeroing ................................................... 3-22
3.10.1 Calibration Procedure .................................................................................................... 3-22
3.10.2 Zeroing Procedure ......................................................................................................... 3-23
3.11 Configuring A Side Master/Side Slave Rudder Repeatback (RRB) Interface ................... 3-23
3.12 Initial Tuning ....................................................................................................................... 3-25
3.13 Restoring SCU Configuration Defaults ............................................................................... 3-25
4 ALARM SYSTEM
4.1 Power-Up Self Test ............................................................................................................ 4-1
4.2 Alarm Display and Acknowledgment .................................................................................. 4-2
4.3 Fault Codes ........................................................................................................................ 4-3
5 DIAGNOSTICS
5.1 Diagnostic LED Indicators .................................................................................................. 5-1
ii JA19-8039F
Table of Contents
APPENDICES
Para Page
A CONFIGURATION DATA
A.1 Rudder Gain (RG) and Counter Rudder (CR) Operational Settings .................................. A-1
A.2 Magnetic Fluxgate Compass Calibration ........................................................................... A-2
A.3 Configuration Settings ........................................................................................................ A-4
A.3.1 Configuration Settings Service Setup 1 ..................................................................... A-4
A.3.2 Configuration Settings Service Setup 2 ..................................................................... A-4
A.4 System Configuration .......................................................................................................... A-29
B SERVICE SETUP CONSIDERATIONS FOR NAVIPILOT 4000 TUNING

B.1 Introduction ......................................................................................................................... B-1
B.2 Calculating Tau .................................................................................................................. B-1
B.3 Selecting the Initial Rudder Gain (RG) and Counter Rudder (CR) Values ........................ B-3
C ACRONYMS AND ABBREVIATIONS ..................................................................................... C-1
LIST OF ILLUSTRATIONS
Figure Page
1-1 NAVIPILOT 4000 and Ancillary Equipment ............................................................................ 1-0

1-2 Control and Display Unit (CDU) .............................................................................................. 1-5
1-3 Steering Control Unit (SCU) .................................................................................................... 1-5
1-4 Tau Nomogram ....................................................................................................................... 1-6
1-5 Minimum Turn Rate Order Chart ............................................................................................. 1-7
1-6 Maximum Turn Radius Order Chart ........................................................................................ 1-7
2-1 NAVIPILOT 4000 CDU Display ............................................................................................... 2-1

2-2 Minimum Turn Rate Order Chart ............................................................................................. 2-23
2-3 Maximum Turn Radius Order Chart ........................................................................................ 2-24
2-4 TUNING Display ...................................................................................................................... 2-32
3-1 Steering Control Unit PCB ...................................................................................................... 3-2

3-2 Isolated Proportional Interface PCB ........................................................................................ 3-4
3-3 DC Solenoid Interface PCB ..................................................................................................... 3-9
3-4 DC Solenoid Interface PCB Functional and Interface Diagram (Unswitched Configuration)3-10
3-5 DC Solenoid Interface PCB Functional and Interface Diagram (Switched Configuration) ... 3-11
3-6 AC Solenoid Interface PCB ..................................................................................................... 3-13
3-7 AC Solenoid Interface PCB Functional and Interface Diagram (Unswitched Configuration) 3-14
3-8 AC Solenoid Interface PCB Functional and Interface Diagram (Switched Configuration) ... 3-15
3-9 CAN Interface Unit (CIU) ......................................................................................................... 3-17
3-10 CAN Interface Cable ............................................................................................................... 3-17
3-11 Rudder Repeatback (RRB) Interfaces - Side Master/Side Slave Configuration ..................... 3-24
A-1 Typical MAIN SERVICE SETUP Menu ................................................................................... A-5

A-2 Configuration ID Number ........................................................................................................ A-30
B-1 Tau Formula Nomogram ......................................................................................................... B-2
JA19-8039F iii
NAVIPILOT 4000
LIST OF TABLES
Table Page
1-1 Dimensions and Weights ........................................................................................................ 1-3

1-2 NAVIPILOT 4000 Equipment Part Numbers ........................................................................... 1-3
1-3 Optional Equipment Used with the NAVIPILOT 4000 ............................................................. 1-4
1-4 NAVIPILOT 4000 Interface Specifications .............................................................................. 1-8
1-5 Related Publications ................................................................................................................ 1-10
2-1 NAVIPILOT 4000 CDU Display ............................................................................................... 2-2

2-2 NAV Mode Functionality (Software Versions R or Later)......................................................... 2-12
2-3 NAV Mode Functionality (Software Versions P or Earlier)....................................................... 2-13
2-4 TUNING Display ...................................................................................................................... 2-33
3-1 SCU Jumper Configurations ................................................................................................... 3-1

3-2 STAGE/DUMP Control - Single SCU Controlling a Rudder .................................................... 3-6
3-3 STAGE/DUMP Control - Two SCUs Controlling a Rudder ..................................................... 3-6
3-4 DC Solenoid Interface PCB Jumper Configurations ............................................................... 3-9
3-5 Software-Configurable Alarm Relays ...................................................................................... 3-18
4-1 Fault Codes ............................................................................................................................. 4-3
5-1 Control and Display Unit (CDU) Diagnostic LEDs .................................................................. 5-1
5-2 Steering Control Unit (SCU) Diagnostic LEDs ........................................................................ 5-1
5-3 AC or DC Solenoid Interface PCB Diagnostic LEDs ............................................................... 5-2
A-1 User Settings for Rudder Gain (RG) and Counter Rudder (CR) ............................................ A-1
A-2 Magnetic Fluxgate Compass Calibration Table ...................................................................... A-3
A-3 Service Setup 1 HCS Configuration Settings ........................................................................ A-6
A-4 Service Setup 2 SCU Configuration Settings ....................................................................... A-8
A-5 Service Setup 2 CDU Configuration Settings ...................................................................... A-27
A-6 Service Setup 2 SYS Configuration Settings ....................................................................... A-29
iv JA19-8039F
Table of Contents
SAFETY PRECAUTIONS
The following safety notice conventions are followed throughout this manual:
A WARNING contains an operating or maintenance procedure, practice, condition, statement, etc., which,
if not strictly observed, could result in injury or death of personnel.
A CAUTION contains an operating or maintenance procedure, practice, condition, statement, etc., which,
if not strictly observed, could result in damage to, or destruction of, equipment.
A NOTE contains an essential operating or maintenance procedure, condition or statement which is considered
important enough to be highlighted.
WARNING:
Proper use of the NAVIPILOT 4000 is critical to ship navigation. Careless OR improper use of this
system may result in vessel damage and/or SERIOUS INJURY OR DEATH.
BEFORE using this system, operators MUST be appropriately trained AND familiar with the
warnings, safety instructions and information contained in this manual AND on system
components.
ALWAYS keep technical manuals in a well-known, readily available location.
CAUTION:
NEVER attempt to open ANY system components OR make ANY internal repairs yourself. Only
Sperry Marine trained Service Technicians may service or repair this equipment. Breaking a seal
will void the warranty!
NEVER exceed specified system power OR environmental limits.
NEVER install unauthorized additional cards OR devices into this system.
NEVER provide unauthorized modifications to this system.
JA19-8039F v
NAVIPILOT 4000
Figure 1-1. NAVIPILOT 4000 and Ancillary Equipment
1-0 JA19-8039F
Chapter 1 - Description
CHAPTER 1
DESCRIPTION
1.1 INTRODUCTION
The NAVIPILOT 4000 is a Heading Control System designed to meet or exceed the international standard for
such devices, as established by the Organization for International Standards in ISO 11674. Capabilities and
optional features beyond those specified in ISO 11674 have been included to meet additional customer
requirements. The NAVIPILOT 4000 is installed as part of a NAVINET Steering Control Network, utilizing a
Controller Area Network (CAN) bus architecture. The configuration may include a large variety of ancillary units,
to satisfy the requirements of all types and sizes of vessel. Figure 1-1 shows some of the options available. This
manual will not cover operating procedures for the many varieties of optional devices that may be connected to
the system. For such equipment, the user must consult the technical manual for the specific device.
1.2 FEATURES
The standard features of the NAVIPILOT 4000 include:

Heading keeping with minimum rudder motion.
Course change control by setting either turn rate or turn radius.
Rudder limit setting (available as an alternative to setting rate or radius).
Two redundant non-isolated analog outputs, configurable as proportional rudder order or proportional
rudder error.
Direct RS-422 connection to external heading reference or navigation systems.
Full alarm complement via the display unit and the alarm contacts.
Optional features include Adaptive Self-Tuning, and NAV or TRACK mode steering. These options will be
configured at installation when specified.
The Adaptive Self-Tuning feature adds:

Adaptive steering control. The NAVIPILOT 4000 automatically adjusts control settings as sea conditions
change, to continuously provide the best possible steering performance and efficiency.
Self-tuning capability. The NAVIPILOT 4000 monitors performance, and automatically adjusts rudder
gain and counter rudder settings as needed, to keep the tuning optimized even if vessel behavior is
affected by changes in loading or trim.
Either NAV or TRACK mode is configured for use when the NAVIPILOT 4000 is connected to a compatible
external navigation system which executes a programmed voyage plan:
NAV mode is designed for use when the NAVIPILOT 4000 is interfaced to Sperry Marines Voyage
Management System (VMS). When NAV mode is selected, the VMS computes the heading order
required to keep the vessel on the plan track line, and sends the computed order to the NAVIPILOT 4000
in the form of Heading to Steer Commands (HSC messages). NAV mode course changes are executed
at wheel-over points, which are calculated by the VMS based on vessel characteristics and the planned
turn radius. When the vessel reaches the wheel-over point, the VMS changes the HSC gradually,
controlling the vessels progress through the course change.
JA19-8039F 1-1
NAVIPILOT 4000
TRACK mode is designed for use when the NAVIPILOT 4000 is interfaced to a GPS, or to a type of
electronic chart system other than the Sperry VMS. A voyage plan must be programmed and active at
the connected system to use Track mode. The GPS or chart system calculates the bearing to the next
waypoint, calculates Cross-Track Error (XTE) with respect to the plan, and sends this data to the
NAVIPILOT 4000. When TRACK mode is selected, the NAVIPILOT 4000 uses the data to compute the
heading order required to stay on the plan, and automatically adjusts the set heading.
IMPORTANT SAFETY NOTE: The external systems configuration settings and user selections can have a
significant effect on the operational characteristics of the NAVIPILOT 4000 in NAV or TRACK mode. The
available modes must be adequately tested and validated at sea. The person in charge of vessel
navigation must establish safe and appropriate guidelines for using the system, based on observed
performance. All users must understand and accept any limitations of the NAV or TRACK interface, and
receive the appropriate familiarization training, before attempting to utilize NAV or TRACK mode at the
NAVIPILOT 4000.
1.3 EQUIPMENT DESCRIPTION
Table 1-1 provides the dimensions and weights of the NAVIPILOT 4000 equipment. Table 1-2 lists the equipment
part numbers. Table 1-3 lists the options that can be purchased with the NAVIPILOT 4000. The part numbers
listed in these tables are associated with the following organization within Northrop Grumman Systems Corporation
(Sperry Marine):
Northrop Grumman Sperry Marine GmbH and Co. KG

Woltmanstrasse 19
D-20097
Hamburg, Germany
1.3.1 Control and Display Unit (CDU)
The CDU (Figure 1-2) contains the operator controls and indicators used for Heading Control System operation.
The CDU provides displays that indicate the current heading, the ordered heading (set heading), and related
information. The CDU contains a Liquid Crystal Display (LCD), which displays information during installation,
operation, and troubleshooting. Also included on the CDU are controls used for testing the system, for adjusting
the intensity level of the CDU indicators for day or nighttime viewing, and a control that is used for muting the
audible alarm.
1.3.2 Steering Control Unit (SCU)
The SCU (Figure 1-3) contains a microcomputer, input/output terminals, and other control circuitry required for
processing the steering commands and controlling the steering gear.
1.3.3 NAVINET 4000 Steering Control Network
The NAVINET 4000 Steering Control Network provides communications between the SCU, the CDU, and various
bus interface devices. The NAVINET 4000 Steering Control Network utilizes a 120-ohm controlled-impedance
Controller Area Network (CAN) bus. CAN is a two-wire, half-duplex, serial network technology which is well
suited for high-speed microcontroller applications. In the NAVINET 4000 implementation:
The data transfer rate of the bus is 250 kilobits per second (kbps).
The maximum length of the backbone is dependent on the type of Bus Interface Units being used. For a
configuration in which the Bus Interface Units are version 0.16.03 or later, the maximum bus length is 200
meters. In all other configurations, the maximum bus length is 100 meters.
When the NAVINET 4000 bus is powered by the SCUs internal 15v bus power supply, up to 30 devices can be
connected to the bus. Each end of the bus must be terminated with a 120-ohm resistor.
1-2 JA19-8039F
Table 1-1. Dimensions and Weights
Control and Display Unit (CDU)
Width 287.8 mm
Height 143.8 mm
Depth 44 mm (requires 150 mm minimum clearance for interface cable)
Weight 1.5 kg
Steering Control Unit (SCU)
Width 413 mm
Height 400 mm (requires 550 mm minimum for interface cable clearance)
Depth 152 mm (requires 280 minimum clearance for cover removal)
Weight 4.2 kg
Table 1-2. NAVIPILOT 4000 Equipment Part Numbers
Part Number Description Notes
NAVIPILOT 4000 Control and

74705 Includes cable 20456.
Display Unit (CDU)
ADG 4000 Control and Display Unit Superseded by part number

74706
(CDU) 74705. Includes cable 20456.
4000 Series Steering Control Unit

74707 --
(SCU)
20456 Cable For replacement purposes.
JA19-8039F 1-3
NAVIPILOT 4000
Table 1-3. Optional Equipment Used With the NAVIPILOT 4000
Part
Description Function
Number
20040 AC Solenoid Daughter Interface to steering gear. 24-230VAC, 4 ampere in rush, 1

PCB (without relay- ampere holding maximum.
switched I/O)
20041 AC Solenoid Daughter Interface to steering gear. 24-230VAC, 4 ampere in rush, 1

PCB (with relay-switched ampere holding maximum.
I/O)
20042 DC Solenoid Daughter Interface to steering gear. 12-110VAC, 2 amperes maximum.

PCB (without relay-
switched I/O) Pump on sense: contact closure < 1 ohm ON, 100K OFF.
20043 DC Solenoid Daughter Interface to steering gear. 12-110VAC, 2 amperes maximum.

PCB (with relay-switched
I/O) Pump on sense: contact closure < 1 ohm ON, 100K OFF.
20044 Isolated Proportional PCB Interface to steering gear. 4-20 mA output or +10VDC output
(maximum load +1 amp).
Current loop: Loop impedance 20 to 150 ohms.
Current loop (4-20mA) must be configured before use.
Pump on sense: contact closure < 1 ohm ON, 100K OFF.
22196 CAN Interface Unit (CIU) Interface of devices to the NAVINET 4000 Steering Control
Network bus
1-4 JA19-8039F
Figure 1-2. Control and Display Unit (CDU)
Figure 1-3. Steering Control Unit (SCU)
JA19-8039F 1-5
NAVIPILOT 4000
1.4 TECHNICAL DATA
1.4.1 Vessel Application Rules
The NAVIPILOT 4000 is applicable to vessels meeting the following requirements:

Vessel Type - Displacement Hull
Vessel Size - Any
Vessel Speed - Up to 35 knots
Vessel Steering Devices - Any of the following: Rudders, Azimuthing Propellers, Azipods.
In order to use the Adaptive Self-Tuning capabilities of the NAVIPILOT 4000, the vessel must be rudder-
controlled, with a Tau greater than or equal to 5 seconds. Tau is the time (in seconds) that it takes the vessel to
sail its own length (at waterline) at its service speed. Figure 1-4 is a nomogram for determining Tau; refer to
Appendix B for additional information on calculating Tau.
Tau (seconds) = 40 35 30 25
20
300
250
15
Ship Length (meters)
200
10
150
100
5
50
2
0
5 10 15 20 25 30
Service Speed (knots)
Figure 1-4. Tau Nomogram
The NAVIPILOT 4000s minimum turn Rate Order and maximum turn Radius Order are also dependent on the
vessels Tau. Figure 1-5 shows the minimum turn rate as a function of Tau; Figure 1-6 shows the maximum turn
radius as a function of Tau and the actual speed of the ship. For NAVIPILOT 4000 software releases R and later,
these Rate Order and Radius Order limitations are imposed by the software. For releases P and earlier, the
operator is responsible for setting Rate and Radius Orders in accordance with these limitations.
1-6 JA19-8039F
NOTE: The operator may have to select a higher turn Rate Order than
shown, in order to control heading in high winds.
65.0
Yacht (16m, 18kt)
Minimum Turn Rate Order setting (dpm) 60.0
Examples of minimum Turn Rate Order settings
55.0
for some typical vessel types are given.
50.0
45.0
40.0
35.0
Yacht (18m, 10kt)
30.0 Cruise Ships:
Tug Boat (32m, 12kt) (293m, 25kt) to (311m, 22kt)
25.0
X-Pacific Container
20.0 Offshore Work Vessel Ship (262m, 20kt)
(47m, 11kt)
15.0 Ore Carrier
RO-PAX (178m, 22kt)
(194m, 13kt)
CG Cutter(115m, 15kt)
10.0
VLCC
5.0
Coastal Product Tanker (174m, 13kt) (263m, 15kt)
0.0
0 5 10 15 20 25 30 35
Tau (sec) @ service speed
Figure 1-5. Minimum Turn Rate Order Chart
NOTE: The operator may have to select a lower turn Radius Order than
7.00
Maximum turn Radius Order setting (nmi)
@ 35 kt actual speed
6.00
5.00
4.00
3.00
2.00
1.00
@ 5 kt actual speed
0.00
0 5 10 15 20 25 30 35
Figure 1-6. Maximum Turn Radius Order Chart
JA19-8039F 1-7
NAVIPILOT 4000
1.4.2 Interface Requirements
Interface specifications for the NAVIPILOT 4000 are listed in Table 1-4.
Table 1-4. NAVIPILOT 4000 Interface Specifications
Power:
Primary Power Input 24V AC/DC @ 3A, 18 36 VDC range

Backup Supply Input 24 VDC @ 3A, 18 36 VDC range
CDU Power Output 24 VDC @ 1 Amp Max. (unregulated, based on Primary Power)
DC Supply Output 24 VDC @ 0.5 Amp Max. (unregulated, based on Primary Power)
Heading Inputs:
Heading 1 and Heading 2:

Interface Type RS-422, optically isolated
Message Format NMEA 0183
Selectable Message Types HDT (True Heading)
HEHDT (North-Seeking Gyro - True Heading)
NSD (Navigation Status Data)
HDM (Magnetic Heading)
HDG (Heading, Deviation, and Variation)
HCHDT (Magnetic Compass - True Heading)
Message Rate 10 Hz
Fluxgate Interface to C.Plath Jupiter Magnetic Compass
Speed Inputs:
Serial Speed:
Selectable Message Types VBW (Dual Ground/Water Speed)
VHW (Water Speed and Heading)
VTG (Course Over Ground and Ground Speed)
Message Rate 1 Hz
Pulse Speed 200 pulse per nautical mile contact closure input, internal pull-up to
+24V
Navigator Interface:

1-8 JA19-8039F
Table 1-4. NAVIPILOT 4000 Interface Specifications

Selectable Message Types:
NAV Mode (Sperry VMS) HSC (Heading to Steer Command), PROP-HTC (Proprietary Heading
To Complete), HTR (Heading Turn Rate)
TRACK Mode (GPS and APB (Heading/Track Controller [Autopilot] Sentence B)
compatible non-Sperry chart
HSC/XTE (Heading-to-Steer Command/ Cross-Track Error)
systems)
Voyage Data Recorder (VDR) Interface:
Interface Type RS-422, serial output, 9600 baud

Selectable Message Types HTD (Heading/Track Control Data)
RSA (Rudder Sensor Angle)
External System Analog Input +/-10V range, via an onboard isolation amplifier
Repeater Output:
Interface Type RS-422. Configurable to be on or off.

Message Types Depending on heading inputs:
AGHDT (Heading/Track Controller [General] - True Heading)
AGNSD (Heading/Track Controller [General] - Navigation Status
Data)
AGHDM (Heading/Track Controller [General] - Magnetic Heading)
Central Alarm Interface:
Interface Type RS-422. Central Alarm Manager (CAM) or Rudder Repeatback

(RRB) output (not optically isolated). Acknowledge input (optically
isolated).
Alarm Message Format NMEA 0183
Configurable Functions CAM, RRB, Off
Baud Rates 38.4k (RRB)
4800, 9600, 19.2k, 38.4k (CAM)
Alarm Contacts:
Dedicated Primary Supply Failure, Backup Supply Failure, Off Heading Alarm,
System Alarm. NO and NC contacts provided for each. All contacts
rated 115 VAC @ 0.5 A max. or 30 VDC @ 1A max.
Configurable Three configurable relays. NO and NC contacts provided for each. All
contacts rated 115 VAC @ 0.5 A max. or 30 VDC @ 1A max.
JA19-8039F 1-9
NAVIPILOT 4000
1.5 RELATED PUBLICATIONS
Table 1-5 lists Sperry Marine publications related to the NAVIPILOT 4000. These publications describe Sperry
Marine steering control equipment which may be used in conjunction with the NAVIPILOT 4000.
Table 1-5. Related Publications
Number Title Remarks
056336 NAVIGUIDE 4000 - User, Installation, and Contains descriptions of the following equipment:
Service Manual Bus Interface Units (BIUs):
FU Mini-Wheel/Display Unit (FMW)
FU Interface/Display Unit (FID)
Steering Mode Selector (SMS)
Steering Position Selector (SPS)
Dual Rudder Sync Selector (DRS)
Steering Alarm Module (SAM)
Steering Mode Selector/NFU (Non-Followup)
Tiller
Mechanical Mode Switch (MMS)
FU (Followup) Hand Wheel
NFU Override Unit
056246 Proportional Amplifier for Solenoid Valves - --

Changing Factory Settings
056319 Override Control Type 4218 - Operating --

Instructions
056328 Rudder Angle Feedback Unit Type 4968 - --

Operator, Technical, Installation, and
Service Manual
1-10 JA19-8039F
Chapter 2 - Operation
CHAPTER 2
OPERATION
2.1 DISPLAYS
The NAVIPILOT 4000 Control and Display Unit (CDU) display is shown in Figure 2-1. A description of each
display area is provided in Table 2-1.
Figure 2-1. NAVIPILOT 4000 CDU Display
JA19-8039F 2-1
NAVIPILOT 4000
Table 2-1. NAVIPILOT 4000 CDU Display

Item
Title Description
No.
c MODE Display Displays the following information:
a. Mode - The operating mode of the NAVIPILOT 4000:

AUTO The NAVIPILOT 4000 performs automatic heading keeping. Using
heading data from the compass and the operators SET HEADING
setting, the NAVIPILOT 4000 automatically generates rudder
commands as needed to keep the actual heading as close as
possible to the set heading. See section 2.6.1 for details.
NAV An optional mode in which the NAVIPILOT 4000 operates under
the control of the Sperry Marine Voyage Management System
(VMS)/NAVIECDIS. See section 2.6.2 for details.
TRACK An optional mode in which the NAVIPILOT 4000 operates under
the control of a GPS, or of a compatible heading/track control
system other than the Sperry Marine VMS/NAVIECDIS. See
section 2.6.2 for details.
NFU or A Non Follow-Up (NFU) device, such as a tiller, is in control of
STANDBY steering. (An NFU device moves the rudder in the desired
direction, but not to a specific final angle.) The rudder command
signals are sent to the steering gear, independent of the
NAVIPILOT 4000 system. On most vessels, this is considered an
emergency mode of steering. Whether the display indicates NFU
or STANDBY is dependent on the system configurationrefer to
Appendix A (Table A-4) for details.
FU or A Follow-Up (FU) device, such as the ships helm wheel or a
HELM Followup Mini-Wheel (FMW), is in control of steering. (An FU
device commands the steering control equipment to move the
rudder to a specific angle.) Whether the display indicates FU or
HELM is dependent on the system configurationrefer to Appendix
A (Table A-4) for details.
EXTERNAL An external system such as a Dynamic Positioning System (DPS)
or external is in control of steering. The external system sends rudder
system commands through the NAVIPILOT 4000, which routes the signals
name to the steering gear to move the rudder. The external system will
sometimes include its own available modes of operation. A number
of names may be selected as the External System Name to make
the indication more appropriate to the specific type of external
systemrefer to Appendix A (Table A-4) for details.
b. ACTIVE status - When the CDU is the station in control of steering, ACTIVE is
displayed in reverse video below the operating mode.
c. OVERRIDE status - When steering control has been overridden by an external
device, OVERRIDE is displayed in reverse video below the operating mode. For
software versions R and later, the OVERRIDE indication flashes when it is
displayed. See section 2.4 for details.
d HDG SELECT Displays the heading source selected by the operator.

Display
e HEADING Displays the actual heading from the selected compass. **** indicates loss of
Display heading data.
2-2 JA19-8039F
Item
Title Description
No.
f SET HEADING Displays the set heading (heading order).

Display
g PRESET Displays the preset heading value which has been selected using the PRESET
HEADING button and the order control knob.
Display
If manual speed has been selected (and the CDU is in control), this area will display
the selected manual speed (MAN SPD) in knots.
If a Preset Heading function is selected while manual speed is displayed, the Preset
Heading information will be displayed in place of the MAN SPD information as
needed.
h TURN METHOD Displays information on the selected turn method:

Display
RUD LIM Rudder Limit. Maximum rudder angle, in degrees. RL icon in
reverse video indicates that the rudder limit has been reached.
RATE Ordered turn rate, in degrees per minute.
RADIUS Ordered turn radius, in nautical miles. (This method is only
available if the speed source is set to LOG.)
The display will flash if an alarm occurs that forces a change in turn method or in the
turn methods current value. (see also item 10 below).
i WEATHER Displays the gain selection chosen to compensate for sea conditions.
Display
If Adaptive Self-Tuning is enabled, either Manual or Adaptive weather control can be
selected. If Manual weather control is selected, the WEATHER display shows a
number from 1 through 7, which is selectable by the operator. 1 is the highest gain
(for low sea states); 7 is the lowest gain (for high sea states). If Adaptive weather
control is selected, the WEATHER display shows the word ADAPTIVE, and the
NAVIPILOT 4000 automatically adjusts the gain to compensate for sea conditions.
If Adaptive Self-Tuning is disabled, only the Manual mode of weather control is
available, as described above.
j MAGNETIC Displays the magnetic compass correction for the geographical location. This
VARIATION information is displayed if a fluxgate magnetic compass has been connected directly
Display to the NAVIPILOT 4000 SCU. The operator may adjust the variation.
k Soft Key Display the control and monitoring functions that are selectable using the MENU
Displays button and the four soft keys located below the display area.
l ALARM When ALARM is displayed in this area, one or more alarm conditions are present. If
Display the alarm is caused by an Off Heading condition, OFF HDG will also be displayed.
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NAVIPILOT 4000
2.2 POWER-UP
The system in which the NAVIPILOT 4000 is installed must be set to a manual steering mode before the
NAVIPILOT 4000 is powered-up. During power-up, the NAVIPILOT 4000 performs a self-test. After the self-test,
the system beeps once and presents the following start-up screen:
SPERRY MARINE
HEADING CONTROL SYSTEM
DISPLAY: XXXXXXX
PORT 1 XXXXXXX
PORT 2 XXXXXXX Only SCUs present are shown.
STBD 1 XXXXXXX xxxxxxx indicates the software
STBD 2 XXXXXXX part number.
SYSTEM STARTUP
2.3 STEERING CONTROL TRANSFER (TAKEOVER METHOD)
The methods for transferring steering control to or from a NAVIPILOT 4000 Control and Display Unit (CDU) are
dependent on the NAVIPILOT 4000s configuration settings for TAKEOVER METHOD (see Appendix A), and on
the types of external devices included in the steering system. The paragraphs below describe the NAVIPILOT
4000s general functionality with respect to each of the three possible TAKEOVER METHOD configurations:
NONE, CALL UP, or TAKEOVER. Optional units such as a Mechanical Mode Switch or the various types of Bus
Interface Units (see Table 1-5) may be installed as part of the NAVIPILOT 4000 system, and will play a role in the
control transfer process described below. In many cases, the specific devices installed will dictate which method
is configured at the CDU and at optional remote devices.
IMPORTANT SAFETY NOTE: The person in charge of navigation must ensure that all personnel have a
working knowledge of the transfer method(s) used for the particular installation, including optional
override capabilities at devices external to the NAVIPILOT 4000. Inappropriate transfer of control could
result in hazards to navigation, resulting in danger to personnel.
2.3.1 NONE
When the NAVIPILOT 4000 is configured for NONE as the method of steering control transfer, steering control is
transferred to the NAVIPILOT 4000 via a Mechanical Mode Switch, a Bus Interface Unit (see Table 1-5), or some
other type of external device. Pressing the TAKE OVER button at the CDU (see illustration) has no effect. In this
case, the label on the button will normally be masked, to avoid possible misinterpretation of the button function.
2-4 JA19-8039F
2.3.2 CALL UP
When the NAVIPILOT 4000 is configured for CALL UP as the method of steering control transfer:
1. The station in control of steering must make an offer to transfer control.
2. The station taking control of steering must accept that offer.
At the CDU or Bus Interface Unit (see Table 1-5) with control of steering, the operator presses the TAKE OVER
button to offer control. When the CDU makes an offer in this manner, or receives an offer from another location,
READY FOR TAKEOVER is displayed at the CDU in reverse video. (Also, for software versions R and later, the
Preset Heading selection [section 2.6.1] is cancelled at the CDU offering control.) An operator at another CDU or
Bus Interface Unit receiving the offer presses the TAKE OVER button at that device, to complete the transfer and
take control.
To cancel an offer of steering control before it has been accepted, the operator at the station in control presses
TAKE OVER again.
2.3.3 TAKEOVER
When the NAVIPILOT 4000 is configured for TAKEOVER as the method of steering control transfer:
A CDU can take control of steering without a formal offer from the station in control, when the
operator presses the TAKE OVER button.
However, the CDUs ability to take control in this manner is dependent on:
a. The setting(s) of the external mode selection device(s).
b. Whether the CDU is configured to be at the main steering location, or at a remote steering
location.
The main or remote designation of a CDU is established by its configuration setting for LOCATION (see
Appendix A, Table A-5), not by its physical placement. All LOCATION settings for a CDU other than MAIN are
considered to be remote locations. The TAKEOVER method is normally used only when there is more than one
CDU at the main location, and/or more than one CDU at remote location(s). (With a single CDU, one would
normally use the NONE configuration for takeover method, and use a Mechanical Mode Switch or Steering Mode
Selector for control transfer.)
When TAKEOVER method is configured, the specific behavior of the NAVIPILOT 4000 is dependent on the
version of software installed, as described below.
IMPORTANT SAFETY NOTE: When TAKEOVER method is configured, it is important to realize how easy
it is to take control of steering at a new location. Personnel access to locations with takeover devices
must be appropriately restricted or monitored.
2.3.3.1 Software Versions R and Later
For a CDU at the main steering location:
2. If a Mechanical Mode Switch (MMS) (see Table 1-5) is used for steering mode selection, the switch
must be set to AUTO for a main steering CDU to be able to take control of steering.
a. When the MMS is changed to AUTO from any other mode setting, READY FOR TAKEOVER is
displayed at each main steering CDU in reverse video, and any main steering CDU can take
control by pressing TAKE OVER.
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NAVIPILOT 4000
b. As long as the MMS remains set to AUTO, the operator at any main steering CDU can take
control from any other main steering CDU by pressing the TAKE OVER button.
3. If a Steering Mode Selector (SMS) (see Table 1-5) is used for steering mode selection, a main steering
CDU may take control regardless of the SMS setting. If the system was not in AUTO mode when the
CDU took control, the SMS mode display will automatically change to indicate that the system is now in
AUTO mode.
For a CDU at a remote steering location:
1. The MMS or SMS must be set to REMOTE for a remote CDU to be able to take control of steering.
2. When the MMS or SMS is changed to REMOTE from any other mode setting, READY FOR
TAKEOVER is displayed at each remote steering CDU in reverse video, and any remote CDU can take
control by pressing TAKE OVER.
4. As long as the MMS or SMS remains set to REMOTE, the operator at any remote CDU can take control
from any other remote CDU by pressing the TAKE OVER button.
However, if there are two steering control devices on the CAN bus which are configured to be at the same
remote location, such as a CDU and a Followup Mini-Wheel (FMW):
1. An SMS must also be installed at that remote location.
2. To perform takeover of steering control, the operator must press TAKEOVER at the SMS, rather than at
the CDU or FMW.
2.3.3.2 Software Versions P and Earlier
For software versions P and earlier, the TAKEOVER method of control transfer functions as described above for
software versions R and later, with one exception. If a Mechanical Mode Switch (MMS) (see Table 1-5) is used
for steering mode selection, a CDU at the main steering location can take control of steering by pressing the
TAKE OVER button, regardless of the MMS setting. Therefore, the MMS setting may not be consistent with the
actual operating mode of the steering system. For this reason, if an MMS is used, the TAKEOVER method of
control transfer is not recommended for main steering CDUs with software versions P and earlier. If the
TAKEOVER method is used at main steering, it is the responsibility of the operator to ensure that the MMS setting
is changed to indicate the actual operating mode.
2-6 JA19-8039F
2.4 STEERING CONTROL OVERRIDE
The NAVIPILOT 4000 can be configured to allow override of steering control by an external device in various
operating modes. Configuration instructions for the service technician are provided in Appendix A. There are
three types of steering control override:
EXTERNAL OVERRIDE - Override when an external device is actuated, as indicated by a contact-
closure at the SCUs OVERRIDE input (pins 32 and 33).
MINIWHEEL OVERRIDE - Override when a Follow-Up Mini-Wheel (see Table 1-5) is actuated.
ABS OVERRIDE - Override when the main helm wheel is actuated.
2.4.1 External Override and Miniwheel Override
By using the SCU CONFIGURATION - OVERRIDE ACTIVE IN menu (see Appendix A), the service technician
can select the operating modes in which the NAVIPILOT 4000 will allow External Override and Miniwheel
Override. This menu provides the following options (refer to Table 2-1 for mode descriptions):
None.
AUTO, NAV, and TRACK modes.
EXTERNAL mode.
FU mode.
AUTO, NAV, TRACK, and EXTERNAL modes.
AUTO, NAV, TRACK, and FU modes.
AUTO, NAV, TRACK, EXTERNAL, and FU modes.
EXTERNAL and FU modes.
The NAVIPILOT 4000 will allow External Override in each of the configured modes. For Miniwheel Override:
Override capability must be enabled at the Follow-Up Mini-Wheel (FMW). Otherwise, the FMW
cannot override steering control in any mode.
If override capability is enabled at the FMW, the FMW can override steering control in the configured
operating mode(s) as listed above, with one exception. An FMW can never override steering control
when the system is in FU mode, even if FU is configured as one of the modes that can be overridden.
This means, for example, that one FMW cannot override another FMW, nor can it override the main
helm wheel.
When steering control has been overridden by an external device, OVERRIDE is displayed in reverse video below
the operating mode on the CDU display. Also, for software versions R and later:
The OVERRIDE indication flashes when it is displayed.
The NAVIPILOT 4000 can be configured to generate an alarm if steering control is overridden. The
following options are configurable (see Appendix A for details):
a. NONE. No override alarms are generated.
b. FMW. An alarm is generated if Miniwheel Override occurs.
c. EXT. An alarm is generated if External Override occurs.
d. FMW+EXT. An alarm is generated if Minwheel Override or External Override occurs.
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NAVIPILOT 4000
2.4.2 ABS Override
By using the SCU CONFIGURATION - ABS OVERRIDE menu (see Appendix A), the service technician can
enable or disable ABS Override. (ABS Override is normally not enabled unless required by the inspecting
agency.) If ABS Override is enabled, actuation of the main helm wheel will override AUTO, NAV, and TRACK
modes. For override to occur, the wheel must be moved from the center position for more than two seconds, by
more than the value configured by the service technician (3 to 8 degrees). When the helm wheel overrides
control of steering:
OVERRIDE is displayed in reverse video below the operating mode on the CDU display, as described
above for External Override and Miniwheel Override.
An ABS OVERRIDE alarm is generated.
After an ABS override takes place, the steering system should be set to HELM mode. To resume automatic
mode, the system should be set back to AUTO.
2.5 MODE SELECTION
Operating modes for the steering system are described in Table 2-1. A CDU can be used to select AUTO, NAV,
or TRACK operating modes. Other operating modes (NFU/STANDBY, FU/HELM, EXTERNAL) can only be
selected by an external device, such as a Mechanical Mode Switch (MMS) or Steering Mode Selector (SMS). For
instructions on selecting the operating mode using external devices, refer to the technical manual(s) for those
devices (see Table 1-5).
Mode selection can be performed at the CDU only if:

The CDU is the station in control of steering, and
The NAVIPILOT 4000 is configured to allow NAV mode or TRACK mode operation (see
section 2.6.2).
The functionality of mode selection at the CDU is dependent on the version of software used by the NAVIPILOT
4000. Each version is described below.
2.5.1 Software Versions R and Later
To select the operating mode at the CDU in control of steering:
Press the MODE switch. If the NAVIPILOT 4000 is configured to allow NAV mode operation, the
display on the left will appear. If the NAVIPILOT 4000 is configured to allow TRACK mode operation,
the display on the right will appear.
The current operating mode (PILOT MODE) is indicated above the soft key labels. To select a
different operating mode, press the associated soft key.
2-8 JA19-8039F
2.5.2 Software Version P
Press the MODE switch. The display below will appear.
NOTE: If the NAVIPILOT 4000 is configured to allow NAV mode operation, the TRACK soft key is
disabled. If the NAVIPILOT 4000 is configured to allow TRACK mode operation, the NAV soft key
is disabled.
2.5.3 Software Versions N and Earlier
Press the MODE switch. The display below will appear.
SAFETY NOTE: For software versions N and earlier, the NAVIPILOT 4000 will allow the
operator to select NAV mode, even if a non-compatible heading/track control system is used.
NEVER select NAV mode if the NAVIPILOT 4000 is controlled by a system other than the
Sperry Marine VMS/NAVIECDIS. Steering behavior could become unpredictable, resulting in
danger to personnel and to the vessel. See section 2.6.2 for additional information on NAV and
TRACK mode operation.
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NAVIPILOT 4000
2.6 HEADING CONTROL
2.6.1 AUTO Mode.
In AUTO mode, the system performs heading keeping by automatically moving the rudder as needed to keep the
actual heading as close as possible to the set heading. Course changes can be made in AUTO mode either
immediately by turning the Set Heading knob, or by using the two-step Preset and Accept method described
below.
Set Heading
NOTE: The Set Heading controls are functional only when the CDU is the station in control of
steering.
To increase the Set Heading, turn the order knob clockwise. To decrease the Set Heading, turn the
order knob counterclockwise. The Set Heading will increase or decrease in 1 increments as the
knob is turned.
To increase or decrease the Set Heading in 1/10 increments, press and release the 1/10 button,
then turn the order knob. The 1/10 symbol will appear on the display while this function is active,
and the function will timeout automatically.
Preset Heading
NOTE: The Preset Heading function should not be used when an OVERRIDE condition is indicated
at the CDU (see section 2.4). For software versions R and later, the PRESET button is disabled
when the CDU is overridden. For software versions P and earlier, it is the responsibility of the
operator to refrain from using the Preset Heading function when the CDU is overridden.
Press the PRESET button to enable preset heading entry.
To select the Preset Heading value in 1 increments, use the order knob as described in the Set
Heading instructions above.
To select the Preset Heading value in 1/10 increments, use the 1/10 button and order knob as
described in the Set Heading instructions above.
Press ACCEPT to make the preset heading the set heading. The PRESET HEADING value will
clear, and that value will appear as the SET HEADING, indicating that the entered preset heading
has been accepted. If PRESET is pressed prior to ACCEPT, the preset mode is canceled.
NOTE: If an alarm occurs while using the Preset function, pressing the ACCEPT button will first
acknowledge (silence) the alarm. ACCEPT must be pressed a second time to accept the preset
order.
2-10 JA19-8039F
2.6.2 NAV and TRACK Modes
In NAV and TRACK modes, the NAVIPILOT 4000 operates under the control of an external heading/track control
system.
NAV mode is used when the NAVIPILOT 4000 is interfaced to a Sperry Marine Voyage Management System
(VMS)/NAVIECDIS. As described in Appendix A (Table A-4), the NAVIPILOT 4000 is configured for NAV mode
operation by setting the NMEA 0183 message type for the Nav interface to HSC, PROP-HTC, HTR (Heading to
Steer Command, Proprietary Heading To Complete, Heading Turn Rate).
TRACK mode is used when the NAVIPILOT 4000 is interfaced to a GPS, or to a compatible heading/track control
system other than the Sperry Marine VMS/NAVIECDIS. As described in Appendix A (Table A-4), the NAVIPILOT
4000 is configured for TRACK mode operation by selecting one of the following NMEA 0183 message types for
the Nav interface, as appropriate for the external system being used:
APB - Heading/Track Controller (Autopilot) Sentence B.
HSC/XTE - Heading-to-Steer Command/Cross-Track Error.
SAFETY NOTE: For software versions N and earlier, the NAVIPILOT 4000 will allow the operator to select
NAV mode, even if a non-compatible heading/track control system is used. NEVER select NAV mode if
the NAVIPILOT 4000 is controlled by a system other than the Sperry Marine VMS/NAVIECDIS. Steering
behavior could become unpredictable, resulting in danger to personnel and to the vessel.
2.6.2.1 NAV Mode
When the NAVIPILOT 4000 is in NAV mode, the VMS/NAVIECDIS computes the heading order required to keep
the vessel on the voyage plan track line, and sends the computed order to the NAVIPILOT 4000 in the form of
Heading to Steer Commands (HSC). NAV mode course changes are executed at wheel-over points, which are
calculated by the VMS/NAVIECDIS based on vessel characteristics and the planned turn radius. When the vessel
reaches the wheel-over point, the VMS/NAVIECDIS changes the HSC gradually, controlling the vessels progress
through the course change. (NOTE: Although NAV mode is selected at the NAVIPILOT 4000, most versions of
VMS/NAVIECDIS will indicate TRACK mode at the VMS/NAVIECDIS display, because the VMS/NAVIECDIS is
performing a track-keeping function.)
When NAV mode is selected, the turn method (see section 2.11) is automatically switched to Rate Order. The
VMS/NAVIECDIS default turn rate is displayed while on a straight leg in the voyage plan. At a programmed
wheel-over point, the NAVIPILOT 4000 indicates RATE ORDER OFF while the VMS/NAVIECDIS controls the
rate through the turn. The turn method and turn rate cannot be adjusted at the NAVIPILOT 4000 in NAV mode.
During NAV mode turns, the gradually changing heading order, as well as the required rate order, can be viewed
on the VMS/NAVIECDIS display.
In NAV mode, the NAVIPILOT 4000 provides predictable heading control even if there is a failure of the
controlling system during a turn. As described in Appendix A (Table A-4), two LOST NAV options are
configurable:
RES HDG (Resume on Heading). The current heading at the time that NAV mode functionality is lost
becomes the Set Heading.
COMPL TURN (Complete the Turn). When NAV mode functionality is lost, the bearing of the next leg
of the turn becomes the Set Heading, allowing the NAVIPILOT 4000 to complete the turn to the new
course. The COMPL TURN configuration is mandatory under the rules of some classification
societies (including DNV Watch 1), and is optional for other vessels.
The LOST NAV configuration also affects:

The functionality of the NAVIPILOT 4000 Set Heading display during a NAV mode turn, and
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NAVIPILOT 4000
The functionality of the NAVIPILOT 4000 when the operator changes the operating mode from NAV
to AUTO during a turn.
The specific behavior of the NAVIPILOT 4000 for each LOST NAV configuration is dependent on:
The version of software used by the NAVIPILOT 4000.
Whether the NAV STEERING MODE MSG (message) from the VMS/NAVIECDIS is configured for
use (see Appendix A, Table A-4). This message is available only from VMS/NAVIECDIS 7.0 or later.
Table 2-2 describes NAV mode functionality in each LOST NAV and NAV STEERING MODE MSG configuration,
for software versions R or later. Table 2-3 describes NAV mode functionality in each configuration, for software
versions P or earlier.
Table 2-2. NAV Mode Functionality (Software Versions R or Later)
NAV STEERING
LOST NAV
MODE MSG Event Behavior
Configuration
Configuration
Any Any A turn is executed in NAV The Set Heading displayed at the CDU will
mode. change incrementally, in accordance with
the HSC (Heading to Steer Commands)
from the VMS/NAVIECDIS.
RES HDG Any The operator changes the The NAVIPILOT 4000 will Resume on
mode from NAV to AUTO Heading.
during a turn.
YES (see Note) NAV mode functionality is The NAVIPILOT 4000 will automatically
lost during a turn. transition to AUTO mode, and Resume on
Heading.
NO The NAVIPILOT 4000 will generate a NAV

MODE NOT AVAILABLE alarm, and
Resume on Heading. The operator must
then change the NAVIPILOT 4000 from
NAV to AUTO mode.
COMPL TURN YES (see Note) The operator changes the The NAVIPILOT 4000 will Resume on
during a turn.
NAV mode functionality is The NAVIPILOT 4000 will automatically

lost during a turn. transition to AUTO mode, and Complete the
Turn.
NO The operator changes the The NAVIPILOT 4000 will Complete the
mode from NAV to AUTO Turn.
during a turn.
NAV mode functionality is The NAVIPILOT 4000 will generate a NAV

lost during a turn. MODE NOT AVAILABLE alarm, and
Complete the Turn. The operator must then
change the NAVIPILOT 4000 from NAV to
AUTO mode.
NOTE: The NAV STEERING MODE MSG can only be used with VMS/NAVIECDIS version 7.0 or later.
2-12 JA19-8039F
Table 2-3. NAV Mode Functionality (Software Versions P or Earlier)

NAV STEERING
LOST NAV
MODE MSG Event Behavior
Configuration
Configuration
RES HDG Any A turn is executed in NAV The Set Heading displayed at the CDU will
mode. change incrementally, in accordance with
the HSC (Heading to Steer Commands)
from the VMS/NAVIECDIS.
The operator changes the The NAVIPILOT 4000 will Resume on

during a turn.
lost during a turn. transition to AUTO mode, and Resume on
Heading.

Resume on Heading. The operator must
then change the NAVIPILOT 4000 from
NAV to AUTO mode.
COMPL TURN Any A turn is executed in NAV At each wheel-over point, the Set Heading
mode. displayed at the CDU will change to the
bearing of the next leg of the turn.
The operator changes the The NAVIPILOT 4000 will Complete the
mode from NAV to AUTO Turn.
during a turn.
lost during a turn. transition to AUTO mode, and Complete the
Turn.

Complete the Turn. The operator must then
change the NAVIPILOT 4000 from NAV to
AUTO mode.
NOTE: The NAV STEERING MODE MSG can only be used with VMS/NAVIECDIS version 7.0 or later.
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NAVIPILOT 4000
2.6.2.2 TRACK Mode
To operate in TRACK mode, a voyage plan must be programmed and active at the connected system. The GPS
or heading/track control system calculates the bearing to the next waypoint, calculates Cross-Track Error (XTE)
with respect to the plan, and sends this data to the NAVIPILOT 4000. When TRACK mode is selected, the
NAVIPILOT 4000 uses the data to compute the heading order required to stay on the plan, and automatically
adjusts the Set Heading.
The Cross-Track configuration settings (see Appendix A, Table A-3) will affect performance in TRACK mode.
Default values normally provide good results, but adjustments may be needed for certain types of vessels. Only a
Sperry Marine authorized service technician should make these adjustments.
The operator must have a good working knowledge of the connected system before selecting TRACK mode at
the NAVIPILOT 4000. The method used for waypoint course changes will depend on the connected systems
configuration and operator setup. In some cases, the operator must approve the next leg at the connected
system before the vessel steers the new planned course. In other cases, the next leg of the plan is automatically
selected at an operator-specified distance from the waypoint. In some instances, the NAVIPILOT 4000 will steer
the new planned course with no operator action required. It is important that the operator makes appropriate
setup choices at the connected system, so that the course change will be executed as intended.
SAFETY NOTE: Some systems may allow course changes to occur with no alarms or warnings. The
operator must monitor progress on the voyage plan, and be prepared to take appropriate actions when
approaching plan waypoints. If there is any uncertainty with regard to how the connected system will
respond at the waypoint, the operator should switch the NAVIPILOT 4000 to AUTO mode to make the
course change. TRACK mode operation can be resumed on the next leg of the plan, after the operator
verifies that the connected system has selected the appropriate waypoint.
If a turn is made in TRACK mode, the NAVIPILOT 4000 controls the turn using the operator-selected turn method
(section 2.11), and the selected value for rudder limit, turn rate, or turn radius (section 2.12). If it becomes
necessary to change the turn method or adjust the associated values, the NAVIPILOT must be switched out of
TRACK. These values cannot be adjusted while TRACK mode is selected.
The Track Error display option (section 2.17) becomes available when TRACK mode is selected. The bar graph
and numeric readout of cross-track error represent truncated values to a resolution of 0.1 nautical mile. This
display should not be used when a precise indication of XTE is desired. The external system will normally provide
a more precise display of XTE.
2-14 JA19-8039F
2.7 SELECT HEADING REFERENCE
This feature is used to select the heading source from the configured heading inputs.
Press to select heading source.
NOTE: The HDG SELECT control is not functional if any of the following conditions exist:
1. The CDU is not the station in control.
2. The system is in an automatic mode (AUTO, NAV, or TRACK).
3. There is only one heading source.
4. The heading source is selected via an external unit.
Heading sources are dependent on the system in which the NAVIPILOT 4000 is installed. A typical
display is shown below.
Press corresponding soft key for desired heading source. NOTE: When the heading source is lost,
asterisks are displayed for Heading in the main display area.
SAFETY NOTE: In some installations, an external compass monitor unit such as the Navitwin III is used to
change the heading source. The operator should not change the source of heading while in an automatic
mode of steering, particularly if there is a significant difference between the heading data. Normally, the
compass monitor is connected in a way that allows mode detection. In this case, the compass selection
is disabled while the NAVIPILOT 4000 is in AUTO, NAV, or TRACK mode. The operator should verify that
the compass monitor does not allow selection of a new source while in an automatic steering mode, by
performing a test in an appropriate operational setting.
JA19-8039F 2-15
NAVIPILOT 4000
2.8 DISPLAY ADJUSTMENT AND TEST
Display Illumination
Press key. Display becomes darker.
Press key. Display becomes brighter.
Display Contrast
Press and hold keys simultaneously. The display contrast decreases
Press and hold keys simultaneously. The display contrast increases.
NOTE: To view a display of the contrast settings while the contrast is being
increased or decreased, first press the menu key repeatedly until no labels are
displayed for the soft keys. While the display contrast is being adjusted, a display
will appear showing TEMPERATURE, CONTRAST, and SELECTION. The
display contrast is temperature-sensitive; the SELECTION value indicates the
selected curve used by the NAVIPILOT 4000 to compensate for temperature
variations.
Press and hold keys simultaneously. This sets the display contrast to its default
value. This also displays the introductory screen that shows the software version.
(This function is disabled when the CDU is the station in control.)
Display Test
Press and hold keys simultaneously. All display elements are activated, and the
alarm buzzer sounds. (This function is disabled when the CDU is the station in
control.) The appearance of the display during the test depends on the contrast
settings that were in effect. If the display was showing dark text on a light
background (normal contrast), the entire display becomes dark during the test. If
the display had been showing light text on a dark background (inverse contrast),
the entire display becomes light during the test.
2-16 JA19-8039F
2.9 SET WEATHER CONTROL
This feature is used to tailor the steering performance for different weather conditions and heading keeping
requirements. The procedure for using this feature is dependent on whether the Adaptive Self-Tuning feature of
the NAVIPILOT 4000 is enabled.
NOTE
The weather control is only functional
when the CDU is the station in control of
steering (in an automatic mode), or when
the CDU is at the location of the station
in control (in a manual mode).
2.9.1 Set Weather Control (Adaptive Self-Tuning Not Enabled)
Press to select weather control.
Select soft key to decrease (<) or increase (>) the WEATHER value. 1 is for low seas (high gain -
tight heading keeping); 7 is for high seas (low gain - relaxed heading keeping).
EXIT clears the menu.
JA19-8039F 2-17
NAVIPILOT 4000
2.9.2 Set Weather Control (Adaptive Self-Tuning Enabled)
Press to select weather control.
Press soft key to select ADAPTIVE or MANUAL. In ADAPTIVE mode, the NAVIPILOT 4000
automatically adjusts the setting as sea conditions change, to continuously provide the best possible
steering performance and efficiency. In MANUAL mode, the operator manually sets a specific setting,
as described below.
If MANUAL mode was selected, the display above will appear. Select soft key to decrease (<) or
increase (>) the WEATHER value. 1 is for low seas (high gain - tight heading keeping); 7 is for high
seas (low gain - relaxed heading keeping).
EXIT clears the menu.
2-18 JA19-8039F
2.10 SET MAGNETIC VARIATION
This menu is displayed only if a fluxgate magnetic heading source is connected directly to the NAVIPILOT 4000,
and the NAVIPILOT 4000 is configured to use a fluxgate heading source. This feature is used to input the correct
magnetic variation for the vessels current location.
Press to select menu display to access magnetic variation menu control.
Press the MAGNETIC VARIATION soft key to select magnetic variation.
Press the < and/or > soft keys to change the value. The current value is the value used.
Press the EXIT key to clear the menu.
JA19-8039F 2-19
NAVIPILOT 4000
2.11 SET TURN METHOD
This feature is used to select rudder limit (RUD LIM), turn rate order (RATE), or turn radius (RADIUS) as the
turning method used with the NAVIPILOT 4000.
Press to select menu display to access turn method menu.
Press soft key to select turn method menu.
Use soft key to select turn method. The RADIUS turn method can only be selected if LOG (speed log)
is selected as the speed source. If speed log messages are lost during a radius-controlled turn, the
turn method will automatically change to RATE, and an equivalent rate order will be computed based
on the current radius order and last known speed.
SAFETY NOTES:
For all turn methods, it is possible to set values that are not appropriate and/or not possible given the
vessels maneuvering characteristics or present operating conditions (weather, speed, load, draft,
etc.). It is important for the operator to verify that the speed input is accurate, the desired turn method
has been selected, and appropriate values have been set before using the NAVIPILOT 4000 to make
a course change.
Although the NAVIPILOT 4000 disables the RADIUS turn method unless a speed log is selected as
the speed source, some speed logs allow manual input of speed data. For the RADIUS turn method,
the speed log must be providing actual measured speed at all times for accurate turn control.
NEVER use the RADIUS turn method with manual speed inputs to the speed log. Incorrect speed
will cause incorrect radius control, potentially causing serious hazards for the ship and personnel.
2-20 JA19-8039F
2.12 SET VALUE
The operator-selectable value for controlling the turn is dependent on the selected turn method: Rudder Limit,
Turn Rate, or Turn Radius. Refer to section 2.11 for instructions on selecting turn method. In each case, the
operator uses the SET VALUE button and the soft keys, as described below.
NOTE
The SET VALUE control is only
functional when the CDU is the station
in control of steering (in AUTO mode),
or when the CDU is at the location of
the station in control (in a manual
mode).
2.12.1 Set Rudder Limit
If the RUD LIM turn method is selected (see section 2.11), pressing the SET VALUE button displays the RUD
LIMIT control menu. The rudder limit can be set to a value between 1 degree and the maximum rudder angle
configured by the service technician (see Appendix A, Table A-4).
The NAVIPILOT 4000 also has a configurable Speed Scaled Rudder Limit (SSRL), which applies regardless of
the set rudder limit or turn rate/radius order. Refer to Appendix A, Table A-3 for a description of the Speed Scaled
Rudder Limit.
When the rudder reaches the limit set by the operator, RL is displayed in inverse video at the bottom of the turn
method display area. RL will also be displayed if the Speed Scaled Rudder Limit is reached. When counter-
rudder is being applied to stop vessel momentum at the conclusion of an ordered heading change, the rudder limit
may temporarily be exceeded if necessary.
Press to select rudder limit.
Select soft key to change value. Select EXIT to clear menu.
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NAVIPILOT 4000
2.12.2 Set Rate Order
If the RATE turn method is selected (see section 2.11), pressing the SET VALUE button displays the RATE ORD
control menu.
Press to select rate order.
When a course change is ordered in AUTO mode, the rudder will move as needed to achieve the rate order.
The minimum turn Rate Order is dependent on the vessels Tau (the time in seconds that it takes the vessel to
sail its own length at its service speed). See Appendix B for the procedures for calculating Tau. Figure 2-2
shows the minimum turn rate as a function of Tau.
For NAVIPILOT 4000 software versions R and later:

The Rate Order limitations shown in Figure 2-2 are imposed by the software.
The screen displays the available range for Rate Order selection (from the imposed minimum to a
maximum of 300 degrees/minute).
For NAVIPILOT 4000 software versions P and earlier:

The Rate Order limitations shown in Figure 2-2 are not imposed by the software. The operator is
responsible for setting Rate Orders in accordance with these limitations.
The screen displays the available range for Rate Order selection (from 1 to 300 degrees/minute).
However, whether or not the software imposes Rate Order limitations, the operator is responsible for setting
values that are safe and reasonable for the particular vessel.
Also, although rate control is normally the preferred method for controlling course changes, rate control may be
degraded on certain types of vessels, such as small craft with fast yaw rates in combination with coarse rudder
control (such as with solenoids). Such limitations should be identified during sea trial of the system, after the
system has been properly tuned and the values for Tau, Rudder Gain (RG), and Counter Rudder (CR) have been
set appropriately (see Appendix B). If turns cannot be adequately controlled using the Rate Order method, the
Rudder Limit method should be used instead (see section 2.12.1).
SAFETY NOTE: If maneuvers are not sharply initiated or heading is not adequately held during times of
significant wind, the operator may need to increase the turn Rate Order above the minimum or typical
rate. This will produce a greater rudder angle for initiating turns, to compensate for the combined effects
of the wind and waves.
2-22 JA19-8039F
NOTE: The operator may have to select a higher turn Rate Order than
65.0
Yacht (16m, 18kt)
Minimum Turn Rate Order setting (dpm) 60.0
Examples of minimum Turn Rate Order settings
55.0
for some typical vessel types are given.
50.0
45.0
40.0
35.0
Yacht (18m, 10kt)
30.0 Cruise Ships:
Tug Boat (32m, 12kt) (293m, 25kt) to (311m, 22kt)
25.0
X-Pacific Container
20.0 Offshore Work Vessel Ship (262m, 20kt)
(47m, 11kt)
15.0 Ore Carrier
RO-PAX (178m, 22kt)
(194m, 13kt)
CG Cutter(115m, 15kt)
10.0
VLCC
5.0
Coastal Product Tanker (174m, 13kt) (263m, 15kt)
0.0
0 5 10 15 20 25 30 35
Figure 2-2. Minimum Turn Rate Order Chart
2.12.3 Set Radius Order
If the RADIUS turn method is selected (see section 2.11), pressing the SET VALUE button displays the RAD
ORD control menu.
Press to select radius order.
When a course change is ordered in AUTO mode, the rudder will move as needed to achieve the radius order.
The system uses the present Log speed to calculate the required rate to achieve the ordered radius. If Log input
is not available, Radius Order control cannot be used.
JA19-8039F 2-23
NAVIPILOT 4000
Figure 2-3 shows the maximum turn radius as a function of Tau and speed. (See Appendix B for the procedures
for calculating Tau.)
NOTE: The operator may have to select a lower turn Radius Order than
7.00
Maximum turn Radius Order setting (nmi)
6.00
5.00
4.00
3.00
2.00
1.00
@ 5 kt actual speed
0.00
0 5 10 15 20 25 30 35
Figure 2-3. Maximum Turn Radius Order Chart
For NAVIPILOT 4000 software versions R and later:

The Radius Order limitations shown in Figure 2-3 are imposed by the software.
The screen displays the available range for Radius Order selection, from 0.01 nautical miles (NM) to
the imposed maximum.
For NAVIPILOT 4000 software versions P and earlier:

The Radius Order limitations shown in Figure 2-3 are not imposed by the software. The operator is
responsible for setting Radius Orders in accordance with these limitations.
The screen displays the available range for Radius Order selection, from 0.01 to 20 NM.
However, whether or not the software imposes Radius Order limitations, the operator is responsible for setting
values that are safe and reasonable for the particular vessel.
If maneuvers are not sharply initiated or heading is not adequately held during times of significant wind, the
operator may need to decrease the turn Radius Order below the maximum or typical radius. This will produce a
greater rudder angle for initiating turns, to compensate for the combined effects of the wind and waves.
2-24 JA19-8039F
2.13 SELECT SPEED SOURCE
This menu is used to select the speed source (either a speed log or manual speed input).
As described in Appendix A, Table A-4, the NAVIPILOT 4000 is configurable for several types of message
formats for speed log inputs. If the NMEA 0183 VBW (Dual Ground/Water Speed) message is used, water speed
has preference. Ground speed is used by the NAVIPILOT 4000 only when water speed is not available.
If manual speed is selected, it is important to set a value as close as possible to the actual vessel speed. If vessel
speed changes significantly, the operator must adjust the manual speed value. When manual speed is used, the
active CDU provides an indication on the display (MAN SPD xx KN) as a reminder.
Manual speed inputs cannot be used with the RADIUS turn method (see section 2.11). If a manual speed input is
selected when RADIUS turn method is being used, the NAVIPILOT 4000 will automatically switch to the RATE
turn method, with a rate order based on the last radius order and log speed.
Press to select menu display to access speed source menu.
Press soft key to select speed source menu.
Press soft key to select LOG or MANUAL speed source.
If manual speed is selected, press < or > key to change value. Press CANCEL to cancel action, or
press ACCEPT to accept value change.
JA19-8039F 2-25
NAVIPILOT 4000
2.14 SET OFF-HEADING LIMIT
The limit is used to activate an alarm if the heading deviates from the set heading by more than the operator-
selected limit for longer than the configured off-heading delay. The off-heading delay can only be adjusted in the
SERVICE SETUP 2 menu (see Appendix A).
SAFETY NOTE: The operator-set limit for the Off Heading alarm is temporarily increased when a course
change is initiated, to make nuisance alarms less likely during the maneuver. It is important that the
operator visually confirms that a course change is being controlled as ordered. In the unlikely event that
the system does not successfully control the course change, the Off Heading alarm may not be activated.
Press to select off heading limit.
Press soft key to select off heading menu.
NOTE
The OFF selection is available
only if OFF HEADING ALARM
DISABLE is enabled in the
SYSTEM SETUP 2 menu (see
Appendix A). Some regulatory
agencies do not allow this option.
Press the OFF soft key to disable the Off Heading alarm, or press the LIMIT soft key to change the
Off Heading limit.
If LIMIT was selected, the display above will appear. Use the < and > soft keys to change the off
heading value. Select CANCEL to clear the menu or ACCEPT to accept the value.
2-26 JA19-8039F
2.15 SET HEADING DIFFERENCE LIMIT
This menu is only available if two or three heading sources provide inputs to the NAVIPILOT 4000. This feature
produces an alarm if the difference between the heading values from any two heading sources is greater than the
operator-selected limit.
Press to select HDG DIFF limit.
Press soft key to select HDG DIFF LIMIT menu.
Select soft key to turn off heading difference limit or to change the heading difference value.
Select soft key to change the heading difference value. Select CANCEL to clear the menu or
ACCEPT to accept the value.
JA19-8039F 2-27
NAVIPILOT 4000
2.16 SELECT LOADING
This feature allows the operator to select the gains associated with the ships load condition. The NAVIPILOT
4000 stores a set of tuning parameters (rudder gain, counter rudder, and tune level) for each loading condition.
Refer to section 2.18 for tuning instructions.
Press to select LOADING.
Press soft key to select LOADING menu.
Select soft key to select loading condition. If the NAVIPILOT 4000s Adaptive Self-Tuning feature is
enabled (see Appendices A and B), the loading options are LIGHT and LOADED. If the Adaptive
Self-Tuning feature is not enabled, the loading options are LIGHT, MEDIUM, or LOADED.
2-28 JA19-8039F
2.17 CHANGE DISPLAY OPTIONS
The DISPLAY OPTIONS feature allows the operator to graphically display the rudder order (RUD ORD), rudder
angle (RUD ANG), turn rate (TURN RATE), track error (TRACK ERR), or automatic tuning (TUNING) at the
bottom of the display.
Continuously press MENU until DISPLAY OPTIONS is available for selection.
Press soft key to select DISPLAY OPTIONS.
Select soft key to change the selection. Select CANCEL to clear the menu or ACCEPT to accept the
selection.
Press to exit menu. The selected graphical display will appear at the bottom of the display.
Examples of each display are shown below.
JA19-8039F 2-29
NAVIPILOT 4000
RUDDER ORDER DISPLAY.

Rudder order output from the
Steering Control Unit in FU or
A/N/T.
RUDDER ANGLE DISPLAY.

Rudder angle indication from
the steering system.
TURN RATE DISPLAY. This

displays the heading rate
change in degrees per minute.
CROSS TRACK ERROR

DISPLAY. This displays the
cross track error in TRACK
mode.
TUNING DISPLAY. Refer to

2.18.2.1 for a description of
the displayed data.
NOTE
Two-loop steering control systems do not provide an accurate

feedback of rudder angle to the RUDDER ANGLE display shown
above. (In two-loop systems, the rudder angle feedback comes
from the control loop for the equipment which drives the rudder,
rather than from an actual indication of rudder position.) For
such systems, do not use the NAVIPILOT 4000s RUDDER
ANGLE display.
2-30 JA19-8039F
2.18 TUNING
2.18.1 Overview
The NAVIPILOT 4000 must be properly tuned in order to steer the ship effectively and efficiently. When the
NAVIPILOT 4000 is first installed, parameters are set based on the ships specifications. Then, a tuning
sequence is performed during sea trials, or as soon as possible after the vessel goes to sea. During a tuning
sequence, a series of maneuvers are performed, and the following parameters are adjusted to optimize
NAVIPILOT 4000 performance:
Rudder Gain (RG). The sensitivity of the NAVIPILOT 4000s response to heading errors. RG is also
referred to as Proportional Gain, because it generates rudder orders proportional to the heading error.
Increasing the RG value increases rudder sensitivity.
Counter Rudder (CR). The sensitivity of the NAVIPILOT 4000s response to turn rate. CR is also
referred to as Rate Gain, because it generates rudder orders in direct response to the turn rate of the
ship. Increasing the CR value increases the amount of counter rudder, and hence reduces the
tendency for the ship to overshoot the desired heading.
If Adaptive Self-Tuning is enabled, two tuning modes are available:

AUTO tuning mode. In this mode, the NAVIPILOT 4000 monitors performance (heading overshoot,
heading undershoot, rudder oscillations), and automatically adjusts RG and CR to the optimal values.
MANUAL tuning mode. In this mode, the operator must monitor performance during tuning
maneuvers, and manually adjust RG and CR to the desired values.
MANUAL tuning can be selected to lock in the values after a successful initial AUTO tuning sequence, or AUTO
can remain selected for continued dynamic tuning during normal maneuvers. If the tuning mode remains set to
AUTO after the tuning maneuvers are performed, the NAVIPILOT 4000 will automatically adjust RG and CR as
needed to compensate for changes in sea state, loading, or trim.
If Adaptive Self-Tuning is disabled, only the manual tuning mode is available. Refer to Appendix A, Table A-6 for
instructions on enabling or disabling Adaptive Self-Tuning.
Tuning is performed with heading control in AUTO mode (section 2.6.1), during heading changes of 10 or more.
Maneuvers of less than 10 are generally not good indicators of tuning performance, and in the case of Adaptive
Self-Tuning, the NAVIPILOT 4000 will not allow the system to tune automatically. Tuning will be most effective
with maneuvers of 10 during rudder-limit turns, and manuevers of 20 or more for rate-order or radius-order
turns.
Vessels using the Rate Order or Radius Order turn methods during normal operation should use the Rate Order
turn method while performing the initial tuning sequence. The turn rate should be set to a value that will typically
be used for an automatic course change at service speed. Overshoots may vary if the tuning sequence is
performed using the Rudder Limit turn method instead of Rate Order.
Tuning is best performed in relatively calm seas at normal service speed. Full service speed will provide the best
results during tuning. Ships speed must remain above 50% of service speed for Adaptive Self-Tuning to function.
The performance of the NAVIPILOT 4000s steering algorithm is dependent on an accurate value for the ships
Time Constant (Tau). Tau is the time (in seconds) that it takes the vessel to sail its own length (at waterline) at its
service speed. The tuning process does not affect the Tau value. Therefore, before tuning is performed, it is
critical that an accurate value for Tau value be entered in the Service Setup menus. Also, for Adaptive Self-
Tuning, it is important that appropriate initial values for RG and CR be entered in the Service Setup menus. Initial
overshoot/undershoot is reduced, the time required for tuning is reduced, and the quality of the tuning level
achieved may be significantly improved. Also, if Tuning is reset, RG and CR will be reset to their initial values. If
the initial RG and CR values are not appropriate for the vessel, the NAVIPILOT 4000 may be unable to steer the
JA19-8039F 2-31
NAVIPILOT 4000
ship effectively. Refer to Appendix B for instructions on calculating Tau and selecting initial RG/CR values. Refer
to Appendix A for instructions for entering these values in the Service Setup menus.
The NAVIPILOT 4000 has operator-selectable loading conditions. For Adaptive Self-Tuning operation, two
separate tunings are maintained: Light (for use when the ship is lightly loaded), and Loaded (for use when the
ship is heavily loaded). For Manual Tuning operation, three separate tunings are maintained: Light, Medium, and
Loaded. For each loading condition, a different Tau value may be entered in the Service Setup Menu. Normally,
Tau should be set to the same value for all load conditions. The exception is the case of Notch Tugs, where
two Tau settings can be used for the two operating conditions of the vessel: (1) When the Notch Tug is operating
as an unattached tugboat (in which case the ship length is short, producing a small Tau), and (2) When the Notch
Tug is docked into a ship-shaped hull (producing a much longer ship length, and thus a large Tau). It is important
that the proper loading condition be selected for the current operating condition of the ship.
Tune Level and Sea State affect the Adaptive Self-Tuning performance. Tune Level is an integer value with a
range from 0 to 5, which indicates how effectively the NAVIPILOT 4000 has been tuned to the ship. Tune levels
of 3, 4, or 5 are normally acceptable, providing efficient and effective heading control performance. If the tune
level is 2 or greater, the Adaptive Self-Tuning function will be incrementally suppressed as sea-state influence
increases. This prevents undesirable tuning adjustments that might otherwise occur due to rough sea conditions.
If the Tune Level is 0 or 1, Adaptive Self-Tuning should not be enabled in rough seas, because the self-tuning
process is not effective in rough conditions. Rough conditions are characterized by excessive yawing in the
seaway, and a Seaway Influence (INF) value of 50 or more. Note: Tune Level will always display a value of 0
when Adaptive Self-Tuning is not enabled. The Tune Level and Seaway Influence values are shown on the
TUNING display (section 2.18.2.1).
2.18.2 Tuning Controls and Displays
The controls and displays described in this section are used when tuning the NAVIPILOT 4000. These controls
and displays must be used ONLY as described in the Tuning Procedures (section 2.18.3). NEVER adjust any of
these controls except in accordance with the Tuning Procedures.
2.18.2.1 TUNING Display
The TUNING display is shown in Figure 2-4. Refer to section 2.17 (Change Display Options) for instructions on
how to select the TUNING display. Table 2-4 describes each of the parameters which appear on the TUNING
display.
Figure 2-4. TUNING Display
2-32 JA19-8039F
Table 2-4. TUNING Display

Item Definition Function
RG Rudder Gain The sensitivity of the NAVIPILOT 4000s response to heading errors. RG is
also referred to as Proportional Gain, because it generates rudder orders
proportional to the heading error. Increasing the RG value increases rudder
sensitivity.
CR Counter Rudder The sensitivity of the NAVIPILOT 4000s response to turn rate. CR is also
referred to as Rate Gain, because it generates rudder orders in direct
response to the turn rate of the ship. Increasing the CR value increases the
amount of counter rudder, and hence reduces the tendency for the ship to
overshoot the desired heading.
TIMER Wait Timer During tuning maneuvers, indicates when the next tuning maneuver can be
executed, without interfering with the Adaptive Self-Tuning calculations
associated with the previous maneuver. The timer starts at the value of Tau
(rounded off to the nearest 5-second increment) and counts down by
5-second intervals after a maneuver has been completed. If another
maneuver is started before the timer counts down to zero, then the
maneuver will not be used for tuning.
LVL Tune Level Indicates from 0 to 5 how effectively the NAVIPILOT 4000 has been tuned to
the ship. Level 2 is considered good; Level 3 or above is preferred. A
higher tune level inhibits further changes to the gain values through
automatic tuning. But if the vessel begins to overshoot course changes, or
performance otherwise degrades, the tune level will decrease. The system is
then able to re-tune more quickly (if AUTO tune mode is selected).
PHASE Turn Phase Indicates the different phases of a course change, for reference during the
tuning sequence. The phases are as follows:
Phase 6 A maneuver has been ordered, but the heading is not yet
changing in the direction ordered.
Phase 5 The heading has begun to change in the direction ordered -
initial acceleration has begun.
Phase 4 A steady turn rate has been achieved (not indicated if rudder
limit control is used).
Phase 3 This is the counter-rudder / overshoot phase.
Phase 2 This is the subsequent undershoot phase.
Phase 0 This indicates steady heading keeping after turning is
complete.
The wait timer begins to count down after Phase 0 is indicated.
BIAS Rudder Order Bias The amount of rudder required in order to maintain the heading, given the
ships characteristics and wind effects.
INF Seaway Influence A measure of the effect of waves on the heading-keeping activity. The
displayed values can range from 0 to 250. When the Tune Level is 2 or
greater, Adaptive Self-Tuning will be incrementally suppressed as Seaway
Influence increases. If the seaway influence increases to a value of 75 or
more during the initial tuning sequence, it may be necessary to reset tuning
and start again. If this happens repeatedly it may be an indication that
conditions are not calm enough to tune the system.
JA19-8039F 2-33
NAVIPILOT 4000
2.18.2.2 RUDDER GAIN (RG) and COUNTER RUDDER (CR) Controls
If MANUAL tuning mode is selected (section 2.18.3.2.1), the operator can adjust the rudder gain (RG) and
counter rudder (CR) in accordance with the procedures described below. Refer to section 2.18.1 for a description
of RG and CR. These controls must be adjusted ONLY as described in the Tuning Procedures (section 2.18.3).
NEVER adjust any of these controls except in accordance with the Tuning Procedures.
Press to select TUNING MENU.
Select soft key to select tuning menu.
NOTE
A speed log providing actual
measured speed is recommended
for NAVIPILOT 4000 tuning.
Manually entered speed MUST be
kept up to date if no speed log is
available. Refer to section 2.18.1
for more information on vessel
speed.
Select soft key to change rudder gain or counter rudder gain.
Select soft key to the change value. Select CANCEL to clear the menu or ACCEPT to accept the
value.
2-34 JA19-8039F
2.18.2.3 WEATHER RATIO Control
The WEATHER RATIO control allows the operator to adjust the scaling range for the amount of Rudder Gain
(RG) reduction produced in response to sea conditions. Mathematically, the weather ratio is RGMAX/RGMIN. Lower
values for the weather ratio minimize the range of gain reduction; higher values maximize the range of gain
reduction. The range is from a maximum of 3.0 to a minimum of 1.1.
The WEATHER RATIO must be adjusted ONLY as described in the Tuning Procedures (section 2.18.3). NEVER
adjust this control except in accordance with the Tuning Procedures.
If Adaptive Self-Tuning is enabled:

When the WEATHER control (section 2.9) is set for ADAPTIVE mode, the WEATHER RATIO control
selects the range of RG reduction produced automatically by the Adaptive Self-Tuning function.
When the WEATHER control is set for MANUAL mode, the WEATHER RATIO control selects the
range of RG reduction produced by WEATHER control settings 1 through 7.
If Adaptive Self-Tuning is disabled, the WEATHER RATIO control functions as described above for MANUAL
mode.
Press soft key to select WEATHER RATIO.
Select soft key to the change value. Select CANCEL to clear the menu or ACCEPT to accept the
value.
JA19-8039F 2-35
NAVIPILOT 4000
2.18.3 Tuning Procedures
2.18.3.1 Before Starting the Tuning
Before tuning the NAVIPILOT 4000:
1. The NAVIPILOT 4000 must be configured properly by a Sperry Marine Field Service Engineer, in
accordance with the Service Setup instructions in Appendix A. It is particularly critical that an accurate
value for Tau be entered. Refer to Appendix B for instructions for calculating Tau.
2. The ship should be operating in calm water. Otherwise, tuning results will be poor.
3. During tuning procedures, vessel speed should be as close as possible to the configured service speed.
(Service speed is configured as part of Service Setup, as described in Appendix A.) Use of a speed log,
which provides speed thru water (STW), is recommended. Whenever a source of STW is not available,
the following alternatives may be substituted:
a. Speed over ground (SOG) may be used, provided that the effect on vessel speed due to wind
and current is negligible, so that there is very little difference between STW and SOG.
b. When speed must be manually entered, use the best available reference (such as by propeller
shaft speed) and ensure that the speed entered is up to date at all times.
4. Enough space should be available for making the required heading changes. It is recommended that
10 heading changes be made for RUDDER LIMIT turn methods, and 20 heading changes be made for
RATE order or RADIUS order turn methods.
5. Input the initial settings for the NAVIPILOT 4000 as follows:
a. Set the MODE of operation to AUTO (section 2.4.2).
b. Select the appropriate TURN METHOD (section 2.11):
i. If the RATE order or RADIUS order turn method will be used during normal operation,
select the RATE order turn method for tuning.
ii. If the RUDDER LIMIT turn method will be used during normal operation, select the RUD
LIMIT turn method for tuning.
c. Select the appropriate turn VALUE (section 2.12):
i. If the RATE turn method was selected, set the RATE ORDER (section 2.12.2) to a value
that will typically be used for an automatic course change at service speed.
ii. If the RUD LIMIT turn method was selected, set the RUD LIMIT (section 2.12.1) to a
value that will typically be used for an automatic course change at service speed.
d. Select LOADING based on the current loading condition of the ship (section 2.16).
2-36 JA19-8039F
e. Set the RUDDER GAIN (RG) and COUNTER RUDDER (CR) (section 2.18.2.2). Use the table
below as a guideline for the initial settings:
RG - Normal configurations 1.4
RG - High-lift rudder configurations 0.7
CR 1.0
f. Set the WEATHER RATIO (section 2.18.2.3). Use the table below as a guideline for the initial
setting:
Cargo/container ships, tankers 2.0
Open water work vessels, larger ferries 1.6
Harbor work vessels, smaller ferries 1.2
2.18.3.2 Performing the Tuning
The procedure for performing the tuning is dependent on whether the NAVIPILOT 4000s Adaptive Self-Tuning
capabilities are enabled, as described in the Service Setup instructions in Appendix A.
If Adaptive Self-Tuning is enabled:
1. Select the desired TUNING MODE, as described in section 2.18.3.2.1. The operator can select AUTO
or MANUAL tuning mode. In AUTO mode, the NAVIPILOT 4000 monitors performance, and
automatically adjusts Rudder Gain (RG) and Counter Rudder (CR) as needed, to keep the tuning
optimized even if vessel behavior is affected by changes in loading or trim. In MANUAL mode, RG and
CR are not automatically adjusted. Instead, the operator can manually enter the desired values for RG
and CR, to compensate for the current loading or trim.
2. If AUTO mode is selected, perform the AUTO tuning procedure, as described in section 2.18.3.2.2. If
MANUAL mode is selected, perform the MANUAL tuning procedure, as described in section 2.18.3.2.3.
If Adaptive Self-Tuning is disabled, only the MANUAL tuning procedure is available. Perform the MANUAL tuning
procedure as described in section 2.18.3.2.3.
JA19-8039F 2-37
NAVIPILOT 4000
2.18.3.2.1 Select TUNING MODE
To select the TUNING MODE:
Press the MENU key until the TUNING MODE soft key is displayed, then press the
TUNING MODE soft key.
Press a soft key to select AUTO or MANUAL tuning mode.
If AUTO mode is selected, the RESET TUNING and WEATHER RATIO soft keys will appear. If
MANUAL mode is selected, the WEATHER RATIO, RUDDER GAIN (RG), and COUNTER RUD
GAIN (CR) soft keys will appear.
2-38 JA19-8039F
2.18.3.2.2 Perform AUTO Tuning
NOTE: The tuning values are stored only for the LOADING condition (LIGHT or LOADED) selected at the time of
tuning (see section 2.16). The tuning performed is applicable to the loading condition of the ship at the time of
tuning, and will continue to adjust to loading changes which occur thereafter. If another, significantly different
loading condition will repeatedly occur, then also perform the tuning procedure for that loading condition, with the
other LOADING condition selected.
To perform AUTO tuning:
1. At the CDU, set the DISPLAY OPTIONS to TUNING. Refer to section 2.17 for instructions on how to
select the display options; see section 2.18.2.1 for a description of the TUNING display.
2. Make a 10 heading change.
3. As the turn completes, the heading should approach the set heading, overshoot the set heading slightly,
and then settle on the set heading. Observe the amount of heading overshoot as the maneuver
completes, and wait for the TIMER on the TUNING display to count down to zero.
4. After the timer counts down to zero:
a. If the RATE order turn method is used, make a series of 20 heading changes.
b. If the RUDDER LIMIT turn method is used, make a series of 10 heading changes.
After each heading change, wait for the TIMER to count down to zero before making another heading
change. No self-tuning adjustment is performed if the TIMER is not allowed to reach zero. The TIMER
will count down in five-second increments after the maneuver is finished, starting from the initial value of
Tau (rounded off to the nearest 5). The normal sequence requires approximately four heading changes
to achieve Tuning Level (LVL) 3, which is the goal. However, if conditions do not permit achievement of a
higher Tune Level, LVL 2 is acceptable. If time and space permit, continue on to LVL 4 or 5.
5. If the RATE order turn method is used, further evaluate tuning performance with one or two large turns
(40 to 60), if space permits.
6. Tuning is now complete. Proceed to section 2.18.3.3 (After Completing The Tuning).
The effectiveness of AUTO tuning is affected by the initial settings for RG and CR. The recommended initial
settings for RG and CR (see section 2.18.3.1) work well for most vessels. However, there may be special cases
in which these initial values do not result in acceptable tuning. In such a case, manually tune the NAVIPILOT
4000 as described below, to determine the best final tune settings for the vessel and for the vessels loading
condition. If the necessary RG and CR are significantly different from the normal defaults, request that Sperry
Field Service update the initial values of RG and CR in the service set-up menu accordingly. Thereafter, allow
Adaptive Self-Tuning to continue to adjust to loading changes over time and usage.
JA19-8039F 2-39
NAVIPILOT 4000
2.18.3.2.3 Perform MANUAL Tuning

NOTE: The tuning performed is applicable to the loading condition of the ship at the time of tuning, and will be
stored only for the LOADING condition (LIGHT, MEDIUM or LOADED) selected at the time of tuning (see section
2.16). If other loading conditions will be used, the tuning procedure must be repeated for each loading condition,
with the appropriate LOADING condition selected at the NAVIPILOT 4000.
To perform MANUAL tuning:
1. At the CDU, set the DISPLAY OPTIONS to TUNING. Refer to section 2.17 for instructions on how to
select the display options; see section 2.18.2.1 for a description of the TUNING display.
2. Make a 10 heading change.
3. As the turn completes, the heading should approach the set heading, overshoot the set heading slightly,
and then settle on the set heading. Observe the amount of heading overshoot as the maneuver
completes, and wait for the TIMER on the TUNING display to count down to zero.
4. Adjust Counter Rudder (CR) (see section 2.18.2.2) as follows:
a. If the heading overshoot was greater than 0.5, increase CR by 0.1.
b. If the heading overshoot was less than 0.1 or never overshot past the set heading, decrease CR
by 0.1.
5. If the RATE order turn method is used, make a 20 heading change. If the RUDDER LIMIT turn method is
used, make a 10 heading change.
6. Observe the amount of heading overshoot as the maneuver completes, and wait for the TIMER on the
TUNING display to count down to zero.
7. Adjust Counter Rudder (CR) as follows:
a. If the heading overshoot was greater than 0.5, increase CR by 0.1, and repeat steps 5 thru 7.
b. If the heading overshoot was less than 0.1 or never overshot past the set heading, decrease CR by
0.1, and repeat steps 5 thru 7.
c. If the heading overshoot was between 0.1 and 0.5, the NAVIPILOT 4000 has been correctly
tuned.
8. If the RATE order turn method is used, further evaluate tuning performance with one or two large turns
(40 to 60) if space permits, and adjust CR if necessary.
9. After completing the above procedure:
a. If more rudder response is desired during turns, then repeat the tuning procedure with a higher RG
value, and an initial CR of 1.0.
b. If less rudder response is desired during turns, then repeat the tuning procedure with a lower RG
value, and an initial CR of 1.0.
c. For a vessel with a very effective rudder in combination with a very fast yaw response, rudder
oscillation may occur during Phase 2 of the tuning maneuver (refer to Table 2-4). If this is the
case, reduce RG by 20%, reset CR to 1.0, and return to step 2.
d. Otherwise, tuning is now complete. Proceed to section 2.18.3.3 (After Completing The Tuning).
2-40 JA19-8039F
2.18.3.3 After Completing the Tuning
After completing the tuning procedure:
1. Record the new RG and CR values in Appendix A, Table A-1, for future reference.
2. Tune the WEATHER RATIO setting (see section 2.18.2.3), as follows:
a. With the vessel on a steady heading, set the WEATHER control to 7 (see section 2.9), and
observe the heading-keeping performance with this most relaxed gain selection for heading
keeping.
b. If more accurate course control is desired for this condition, then reduce the WEATHER RATIO
by an increment or two at a time, until a satisfactory result is achieved. Conversely, if less rudder
activity is desired and course control can be allowed to decrease, then increase the range by an
increment or two at a time until a satisfactory result is reached. The WEATHER RATIO setting
should not require further adjustment.
3. Set the WEATHER control as needed for the current conditions, as described in section 2.9.
4. For best performance when not using a speed log, ensure that the NAVIPILOT 4000s manually entered
speed is kept up to date.
2.18.4 Resetting the Tuning
If the NAVIPILOT 4000s Adaptive Self-Tuning function is enabled, the operator has the capability to reset the
tuning of the system back to its starting condition. When Reset Tuning is selected, the tune level value is set to
zero, and the rudder gain (RG) and counter rudder (CR) are set to their initial values, as configured in the Service
Setup menus (see Appendix A). Once the tune level is set to zero, the tune level will not change except by
automatic tuning. In order to perform the Reset Tuning function, the TUNING MODE must be set to AUTO, as
described in section 2.18.3.2.1.
NOTE: The tuning should not be reset unless the tuning performance is so poor that it is better to start tuning
again from the beginning.
Press soft key to select RESET TUNING.
JA19-8039F 2-41
NAVIPILOT 4000
Press RESET soft key to reset the automatic tuning, or press EXIT to cancel the action.
2.19 VIEWING AND ACKNOWLEDGING ALARMS
The alarm subsystem of the NAVIPILOT 4000 provides the operator with audible and visual indications of system
faults. The audible indication is via a piezoelectric buzzer in the CDU, as well as alarm relay contacts, which may
be connected to an optional external alarm system. The visual indications at the CDU include a flashing ALARM
indication, and an alarm list accessible via the menu button. The flashing ALARM indication is displayed using
inverse video, and becomes steady when the alarm is acknowledged. Refer to Chapter 4 (Alarm System) for
instructions on viewing and acknowledging alarms.
2.20 EMERGENCY OPERATION
Refer to Chapter 4 (Alarm System) for instructions on diagnosing NAVIPILOT 4000 failures. In case of
NAVIPILOT 4000 failure, the operator should use manual control.
2-42 JA19-8039F
Chapter 3 Installation and Initialization
CHAPTER 3
INSTALLATION AND INITIALIZATION

3.1 STEERING CONTROL UNIT (SCU) HARDWARE CONFIGURATION
Once the Steering Control Unit (SCU) has been installed, the cover must be removed, and the jumpers must be
configured in accordance with Table 3-1. Refer to Figure 3-1 for jumper locations. Using the jumpers, the
technician can select: the rudder unit controlled by the SCU, the power source for the NAVINET 4000 Steering
Control Network bus, the identification number of the SCU in the system, and whether the CAN bus is terminated
at the SCU. The correct configurations of all factory-installed jumpers are also listed, for reference.
Table 3-1. SCU Jumper Configurations
Jumper Function Configuration Notes
E1-E2 Rudder Unit In: Starboard All SCUs that are connected to the same
Selection rudder must have the same setting (all Port
Out: Port
or all Starboard).
For single-rudder vessels in which a
Voyage Data Recorder (VDR) is used, all
SCUs must be set to Starboard. (The VDR
reads the rudder angle from the starboard
field of the NMEA message.)
For dual-rudder vessels, all SCUs that
control the port rudder must be set to Port,
and all SCUs that control the starboard
rudder must be set to Starboard.
E3-E4 NAVINET 4000 In: Internal The internal supply is 15 vdc, 500 mA. If
Steering Control more than 500 mA is required to supply all
Out: External
Network - Bus devices which communicate over the bus,
Power Source an external supply will be required. A diode
is inserted inline with the internal supply, for
protection with parallel SCU operation.
E5-E6 FL2 Selection In Filter FL2 not installed.
E7-E8 FL2 Selection In Filter FL2 not installed.
E9-E10 Not used -- --
E11-E12 Node ID EEPROM In Storage enabled.
E13-E14 Watchdog Timer In Timer enabled.
This jumper is only needed if the system
In: SCU 2 has more than one SCU per rudder. If two
E15-E16 SCU Identification
Out: SCU 1 SCU's are connected to a rudder, set one
SCU to SCU 1 and the other to SCU 2.
E17-E18, Reserved for future use as option selection
Not used --
E19-E20 jumpers.
E21-E22 Not used -- --
NAVINET 4000 See Section 3.3 for bus termination
Steering Control In: Terminated instructions. E23-E24 is either a soldered
E23-E24
Network - Bus Out: Not Terminated bridge (earlier configurations) or a
Termination removable jumper (later configurations).
JA19-8039F 3-1
NAVIPILOT 4000
Jumper Function Configuration Notes
DC/DC Converter
E25-E26 Jumpered;
E25 thru E30 Input Normal/ Normal input.
E28-E29 Jumpered.
Reversed
Connects To J1 Optional Steering Connects To J1

On Optional I/O Board On Optional Factory
Steering I/O Board Mounting Locations Steering I/O Board Use Only
E1-E2 E15-E16 E3-E4 E23-E24 Rev Letter

(Rev B & Of Assy
up only)
Figure 3-1. Steering Control Unit PCB
3-2 JA19-8039F
3.2 OPTIONAL STEERING I/O PCB INSTALLATION AND CONFIGURATION
The optional steering I/O PCBs provide a configurable means for intelligent control of steering gear systems.
Three types of optional steering I/O PCBs are available:
Isolated Proportional Output Interface PCB (section 3.2.1).
Solenoid Interface PCBs (section 3.2.2):
a. DC Solenoid Interface PCB.
b. AC Solenoid Interface PCB.
An SCU can be equipped with up to two steering I/O PCBs. Figure 3-1 shows the locations for installing the
steering I/O PCBs on the SCU PCB. The processor in the SCU will automatically determine if steering I/O PCB(s)
are installed, and the type(s) of card installed.
3.2.1 Isolated Proportional Output Interface PCB
The Isolated Proportional Output Interface PCB (Figure 3-2) provides two analog voltage outputs for rudder
control. The single analog output generated in the SCU is routed into both channels of this circuit board, so both
channels will have the same output. However, both channels are electrically isolated from each other, and from
the internal SCU power supply.
The outputs from the PCB are configurable by the service technician to be either PRO (Proportional to Rudder
Order) or PRE (Proportional to Rudder Error). For PRO outputs, the voltage scaling is configurable over a range
of 80 to 350 millivolts per degree of rudder order. For PRE outputs, the voltage scaling is configurable over a
range of 500 to 2000 millivolts per degree of rudder error. Configuration instructions are provided in Appendix A.
(In the SERVICE SETUP 2 - SCU CONFIGURATION settings, refer to the STEERING GEAR - ANALOG
OUTPUT menu.)
The Isolated Proportional Output Interface PCB employs two small isolation power supplies and two isolation
amplifiers. The amplifiers are limited to a maximum swing of +/- 10 volts. When using the isolated outputs, do not
couple the output return to any power returns or commons in the SCU, or the electrical isolation will be lost.
This PCB also has two 4-20mA current-loop outputs, and two Pump On status inputs. These signals are for
future use, and are not currently supported by the NAVIPILOT 4000.
JA19-8039F 3-3
NAVIPILOT 4000
Figure 3-2. Isolated Proportional Interface PCB (sheet 1 of 2)
3-4 JA19-8039F
Figure 3-2. Isolated Proportional Interface PCB (sheet 2 of 2)
JA19-8039F 3-5
NAVIPILOT 4000
3.2.2 Solenoid Interface PCBs
A Solenoid Interface PCB generates control signals for solenoids that actuate steering pumps, providing the
capability for multi-stage steering pump control. There are two types of Solenoid Interface PCBs:
DC Solenoid Interface PCB (section 0). This PCB generates control signals for dc solenoids using supply
voltages of 12 to 110 vdc.
AC Solenoid Interface PCB (section 3.2.2.2). This PCB generates control signals for ac solenoids using
supply voltages of 24 to 230 vac.
Each Solenoid Interface PCB contains two pump control sections (PUMP 1 and PUMP 2), and each SCU can
have up to two PCBs installed. In the SCU Service Setup menus (see Appendix A), each pump control section of
each Solenoid Interface PCB is individually configurable for a specific stage of pump control. For each
configurable stage, the solenoid is actuated when the rudder error rises above the ON threshold associated with
that stage, and de-actuated when the rudder error falls below the OFF threshold associated with that stage.
Stages of directional valve control are designated STAGE 1 thru STAGE 4 in the SCU Service Setup menus;
stages of dump valve control are designated DUMP 2 thru DUMP 4. (Stage 1 can only be configured for a
directional valve.) For a system with a single SCU controlling a rudder, the ON and OFF thresholds for each
stage are shown in Table 3-2. For a system with two SCUs controlling the same rudder, the staging alternates
between the two SCUs. One SCU will be the Master and the other the Slave. The ON and OFF thresholds for
each stage in this configuration are shown in Table 3-3.
Table 3-2. STAGE/DUMP Control - Single SCU Controlling a Rudder

Threshold
Rudder Error Rudder Error
STAGE or DUMP Configuration
ON Threshold OFF Threshold
Stages
STAGE 1 STAGE 1 the configured value the configured value
for Stage 1 ON for Stage 1 OFF
(default = 0.8) (default = 0.1)
STAGE 2 or DUMP 2 STAGE 2 3* 2
Table 3-3. STAGE/DUMP Control - Two SCUs Controlling a Rudder

Threshold Rudder Error Rudder Error
STAGE or DUMP
Configuration Stages ON Threshold OFF Threshold
STAGE 1 (Master SCU) STAGE 1 the configured value the configured value
for Stage 1 ON for Stage 1 OFF
(default = 0.8) (default = 0.1)
STAGE 1 (Slave SCU) STAGE 2 3* 2
STAGE 2 or DUMP 2 (Master SCU) STAGE 3 5* 4
STAGE 2 or DUMP 2 (Slave SCU) STAGE 4 7* 6
* For revision U software and later the threshold values are adjustable.
3-6 JA19-8039F
When configuring each pump control section of a Solenoid Interface PCB:

The PUMP 1 section can only be configured for actuation of a directional valve, and it can only be
configured to operate as STAGE 1 or STAGE 2.
The PUMP 2 section can be configured for actuation of a directional valve or a dump valve, and it can
be configured to operate as any of the possible stages (STAGE 1 thru STAGE 4; DUMP 2 thru
DUMP 4).
When connecting a pump control section of a Solenoid Interface PCB to the solenoid(s):
If the PUMP 1 or PUMP 2 section is configured for actuation of a directional valve, the Solenoid
Interface PCB provides LEFT and RIGHT output signals from that section for directional control.
If the PUMP 2 section is configured for actuation of a dump valve, the Solenoid Interface PCB
provides the control signal at the LEFT output of that section.
On each Solenoid Interface PCB, each pump control section has an associated Pump On (pump running) status
input. This input can be enabled or disabled for use by the PCB, via the SCU Service Setup menus (see
Appendix A). If the Pump On input is configured for use, that pump control section will be staged only when its
status input indicates that the pump is running. If the Pump On input is not configured for use, it will be ignored,
and the section will always be staged.
If the Pump On inputs are configured for use, the SCU can change the solenoid staging based on pump status.
When a lower-stage pump is off or has failed, the staging will fall back--the next-highest stage pump will be
controlled as if it were the lower-stage pump. For example, if two pump control sections are configured for
Stage 2 and Stage 3 respectively, and the status input indicates that the Stage 2 pump is not running, the Stage 3
section will control its pump according to the Stage 2 rudder error thresholds. For directional valve control, each
section will configure to the next lowest stage, including Stage 1, as appropriate. However, for dump valve
control, each section can never go below Dump 2.
Additionally, in a system with two SCUs controlling the same rudder:

Fall back does not occur across SCUs, as long as there is at least one active pump. For example, if
the Stage 2/Dump 2 (Master SCU) pump is off or has failed, the Stage 3/Dump 3 (Master SCU) pump
will be controlled as if it were the Stage 2/Dump 2 (Master SCU) pump.
If one SCU has no pumps active, and the other SCU on the same rudder has active pumps, the SCU
with active pumps will control the staging as if it were a single SCU controlling the rudder, as
described in Table 3-2.
If both SCUs have no pumps active, then all pumps will become Stage 1, to facilitate emergency
steering if at least one pump is functioning sufficiently to steer the vessel.
JA19-8039F 3-7
NAVIPILOT 4000
3.2.2.1 DC Solenoid Interface PCB
The DC Solenoid Interface PCB generates control signals for dc solenoids using supply voltages of 12 to 110 vdc,
for solenoid control of two steering pumps. Figure 3-3 shows component locations on the PCB.
There are two configurations of the DC Solenoid Interface PCB:
1. Part number 20042. In this configuration, an unswitched I/O interface is used. TB1 is the signal
interface, and relays K5 thru K9 are not installed.
2. Part number 20043. In this configuration, a switched I/O interface is used. TB2 is the signal
interface, and relays K5 thru K9 are installed.
Unswitched Configuration. Figure 3-4 shows a functional block diagram of the unswitched configuration of the DC
Solenoid Interface PCB, and a pinout of the signal interfaces. A 12 to 110 vdc supply voltage is input to the PCB
for each pump. For directional control valves, the PCB supplies Left and Right actuation signals for each pump.
For dump valves, a control signal for the pump is supplied at the Left output of the PCB. However, as described
in section 3.2.2, Pump 1 must always be configured for a directional valve. Only the Pump 2 output can be
configured for dump valve control.
The SCU communicates actuation commands to the DC Solenoid Interface PCB via a serial interface to
connector J1. The PCB converts the serial data to parallel, and latches it to drive four solid-state (MOSFET)
SPST-NO relays. An LED is connected to each output of the latch, to indicate activation of the solenoid. When a
relay is actuated, a diode bridge is biased on, supplying the dc supply voltage input to the associated solenoid-
control output.
Snubber diodes on the board protect against reverse EMF. These diodes must be configured with jumpers to
match the type of drive employed: source (negative dc supply voltage) or sink (positive dc supply voltage). Table
3-4 lists the required jumper settings for each configuration.
The interface card has two optocoupler inputs to monitor the Pump On status signal for each pump. Each Pump
On input is a contact closure (closed = On). The Pump On input must be a low-impedance, potential-free contact.
Switched Configuration. Figure 3-5 shows a functional block diagram of the switched configuration of the DC
Solenoid Interface PCB, and a pinout of the signal interfaces. The switched configuration functions the same as
the unswitched configuration described above, with the following exceptions:
1. The dc supply inputs and solenoid control outputs are enabled or disabled by a set of mechanical
DPST relays. The relays are actuated, and the outputs are enabled, only if the This SCU On
input is active (+24 vdc).
2. The Pump On status input for Pump 1 is +24 vdc when the pump is on, 0 vdc when the pump is
off. This signal actuates a DPST relay, which supplies the contact-closure signal to the PCBs
optocoupler, and also supplies a contact-closure pump status output to the other SCU in a two-
SCU configuration.
3-8 JA19-8039F
Figure 3-3. DC Solenoid Interface PCB
Table 3-4. DC Solenoid Interface PCB Jumper Configurations
Configuration Jumper Installation
Sink Configuration (-) E2-E3, E5-E6, E8-E9, E11-E12
Source Configuration (+) E1-E2, E4-E5, E7-E8, E10-E11
JA19-8039F 3-9
NAVIPILOT 4000
TB1
Pump 1 On
5 (Contact-Closure)
Pump 1 Status Optocoupler
6 Common
+5V 2 Pump 1 Supply

(To All Circuitry) (12-110 vdc)
+24V
(To Optocouplers) Pump 1 Supply
Bridge, 1
Common
Snubbers,
Jumpers
3 Pump 1 Left
Solid-
State
Relay
LED
DS1 Bridge,
Snubbers,
Jumpers 4 Pump 1 Right
Solid-
State
Relay
J1 Clock LED Pump 2 Supply
8
DS2 (12-110 vdc)
Serial
Data Serial to
Pump 2 Supply
Parallel
Converter
Driver
Bridge, 7
Common
Load Snubbers,
LED Jumpers Pump 2 Left
DS3 9
(or Dump)
Solid-
State
Relay
Bridge,
Snubbers,
LED Jumpers 10 Pump 2 Right
DS4
Solid-
State
Relay
11 Pump 2 On
Pump 2 Status (Contact-Closure)
Optocoupler
12 Common
Figure 3-4. DC Solenoid Interface PCB - Functional and Interface Diagram (Unswitched Configuration)
3-10 JA19-8039F
TB2
13 Pump 1 On
(to other SCU)
14 Common
Pump 1 On
5 (+24 vdc)
Pump 1 Status
Optocoupler
6 Common
Common
Pump 1 Supply
2 (12-110 vdc)
+5V
(To All Circuitry) Pump 1 Supply
+24V
(To Optocouplers)
1
Common
Bridge,
Snubbers,
Jumpers
Pump 1 Left
Solid-
3
State
Relay
LED Bridge,
DS1 Snubbers,
Solid-
State
Relay

LED
J1 Clock DS2 Pump 2 Supply
8
(12-110 vdc)
Serial
Serial to
Data
Parallel Driver 7 Pump 2 Supply
Common
Load
Converter Bridge,
Snubbers,
Jumpers

LED Pump 2 Left
DS3
Solid-
9
(or Dump)
State
Relay
Bridge,
LED Snubbers,
DS4
Solid- This SCU On
State 15 (+24 vdc)
Relay
16 Common
11 Pump 2 On
Optocoupler
12 Common
Figure 3-5. DC Solenoid Interface PCB - Functional and Interface Diagram (Switched Configuration)
JA19-8039F 3-11
NAVIPILOT 4000
3.2.2.2 AC Solenoid Interface PCB
The AC Solenoid Interface PCB generates control signals for ac solenoids using supply voltages of 24 to 230 vac,
for solenoid control of two steering pumps. Figure 3-6 shows component locations on the PCB.
There are two configurations of the AC Solenoid Interface PCB:
1. Part number 20040. In this configuration, an unswitched I/O interface is used. TB1 is the signal
interface, and relays K5 thru K9 are not installed.
2. Part number 20041. In this configuration, a switched I/O interface is used. TB2 is the signal
interface, and relays K5 thru K9 are installed.
Unswitched Configuration. Figure 3-7 shows a functional block diagram of the unswitched configuration of the AC
Solenoid Interface PCB, and a pinout of the signal interfaces. A 24 to 230 vac supply voltage is input to the PCB
for each pump. For directional control valves, the PCB supplies Left and Right actuation signals for each pump.
For dump valves, a control signal for each pump is supplied at the Left output of the PCB. However, as described
in section 3.2.2, Pump 1 must always be configured for a directional valve. Only the Pump 2 output can be
configured for dump valve control.
The SCU communicates actuation commands to the AC Solenoid Interface PCB via a serial interface to
connector J1. The PCB converts the serial data to parallel, and latches it to drive four solid-state (SCR-based)
SPST-NO relays. An LED is connected to each output of the latch, to indicate activation of the associated
solenoid. When a relay is actuated, the ac supply voltage input is supplied to the associated solenoid-control
output.
The interface card has two optocoupler inputs to monitor the Pump On status signal for each pump. Each Pump
On input is a contact closure (closed = On). The Pump On input must be a low-impedance, potential-free contact.
Switched Configuration. Figure 3-8 shows a functional block diagram of the switched configuration of the AC
Solenoid Interface PCB, and a pinout of the signal interfaces. The switched configuration functions the same as
the unswitched configuration described above, with the following exceptions:
1. The ac supply inputs and solenoid control outputs are enabled or disabled by a set of mechanical
DPST relays. The relays are actuated, and the outputs are enabled, only if the This SCU On
input is active (+24 vdc).
2. The Pump On status input for Pump 1 is +24 vdc when the pump is on, 0 vdc when the pump is
off. This signal actuates a DPST relay, which supplies the contact-closure signal to the PCBs
optocoupler, and also supplies a contact-closure pump status output to the other SCU in a two-
SCU configuration.
3-12 JA19-8039F
Figure 3-6. AC Solenoid Interface PCB
JA19-8039F 3-13
NAVIPILOT 4000
TB1
Pump 1 On
5 (Contact-Closure)
Pump 1 Status Optocoupler
6 Common
+5V 2 Pump 1 Supply

(To All Circuitry) (24-230 vac)
+24V
(To Optocouplers) Pump 1 Supply
Solid- 1
Common
State
Relay
3 Pump 1 Left

LED
DS1 Solid-
State
Relay 4 Pump 1 Right

J1 Clock
LED Pump 2 Supply
8
DS2 (24-230 vac)
Serial
Data Serial to
Pump 2 Supply
Parallel
Converter
Driver
Solid- 7
Common
Load State
LED Relay Pump 2 Left
DS3 9
(or Dump)

Solid-
State
LED Relay
DS4 10 Pump 2 Right
11 Pump 2 On
Optocoupler
12 Common
Figure 3-7. AC Solenoid Interface PCB Functional Block Diagram (Unswitched Configuration)
3-14 JA19-8039F
TB2
13 Pump 1 On
(to other SCU)
14 Common
Pump 1 On
5 (+24 vdc)
Pump 1 Status
Optocoupler
6 Common
Common
Pump 1 Supply
2 (24-230 vdc)
+5V
(To All Circuitry) Pump 1 Supply
+24V
(To Optocouplers)
1
Common
Solid-
State
Relay
Pump 1 Left
3

LED Solid-
DS1 State

LED
J1 Clock DS2 Pump 2 Supply
8
(24-230 vdc)
Serial
Serial to
Data
Parallel Driver 7 Pump 2 Supply
Common
Load
Converter Solid-
State
Relay

LED Pump 2 Left
DS3 9
(or Dump)

Solid-
LED State
DS4
This SCU On
15 (+24 vdc)
16 Common
11 Pump 2 On
Optocoupler
12 Common
Figure 3-8. AC Solenoid Interface PCB Functional Block Diagram (Switched Configuration)
JA19-8039F 3-15
NAVIPILOT 4000
3.3 NAVINET 4000 STEERING CONTROL NETWORK BUS CONFIGURATION.
The NAVINET 4000 Steering Control Network utilizes a 120-ohm controlled-impedance Controller Area Network
(CAN) bus, with a data transfer rate of 250 kilobits per second.
This bus requires a cable which is approved for compatibility with the CAN requirements (such as the Lapp USA
Unitronic Bus DeviceNet cable, part number 2170 250). Bus communications will not operate reliably over
other types of cable. The CAN cable is divided into two sections: the bus backbone, and the stubs which connect
to individual devices. The backbone must maintain a controlled impedance of 120 ohms. The maximum length of
the backbone at 250 kbps is dependent on the type of Bus Interface Units (BIUs) being used in the system. For a
configuration in which the BIUs are version 0.16.03 or later, the maximum bus length is 200 meters. In all other
configurations, the maximum bus length is 100 meters.
To attach bus devices, a splice with an in-line terminal block or a CAN Interface Unit (CIU) is used to tap into the
bus. Figure 3-9 shows a CAN Interface Unit; Figure 3-10 shows the CAN bus cable stub used to interface to
Heading Control System units.
Each end of the bus must be terminated with a 120-ohm (1/8 watt or greater) resistor. The only exception to this
rule is for a system in which the only devices on the bus are a single Control and Display Unit (CDU) and a single
Steering Control Unit (SCU), which are directly connected together. In this case only, use of a single 120-ohm
resistor at the interface point is adequate termination.
The bus can be terminated in any of the following ways:

Via discrete resistors.
Via resistors R1 and R2 on a CAN Interface Unit.
Via the built-in termination resistor on the Steering Control Unit PCB. (NOTE: Only Revision B or
later SCU PCBs have the built in termination resistor.)
The installer must ensure that no more than two termination resistors are present. Additional termination resistors
may cause unreliable operation of the bus. If more than two devices installed on the bus have built-in termination
resistors, the installer must remove or disconnect those resistors as needed, to ensure that terminations are
present only at each end of the bus. For example:
On the SCU PCB, the termination resistor is connected to the bus when a soldered bridge (earlier
configurations) or a removable jumper (later configurations) is connected across terminal pair
E23-E24 (figure 3-1). If the termination resistor on the SCU PCB is not to be used, remove the bridge
or jumper across E23-E24.
On the CAN Interface Unit, each of the two resistors provides a separate bus termination. Remove
both resistors to provide no bus terminations at the CIU; remove either resistor to provide a single bus
termination at the CIU.
The CAN cable shield must be grounded at only one point on the bus. All other taps or splices must pass the
shield through to the connection at the destination device. Equipment ground and other cable shield grounds
must be kept separate. In all cases, use proper shield grounding techniques, usually connecting the shield to the
vessel hull ground at only one point.
Stubs or taps to bus devices represent a load on the bus. The length of each stub must be less than 3 meters.
Assuming that the CAN bus is powered by the SCUs internal 15V bus power supply, the total number of loads on
the bus should not exceed 30. (Load current for the 15V bus power supply is approximately equal to 25mA +
(N-1)*8mA, where N is the number of nodes or loads.)
3-16 JA19-8039F
Figure 3-9. CAN Interface Unit (CIU)
Figure 3-10. Display CAN Bus Drop Cable
JA19-8039F 3-17
NAVIPILOT 4000
3.4 SOFTWARE CONFIGURATION PARAMETERS.
The NAVIPILOT 4000 software is configured at installation by the service technician after all hardware
connections have been made. The configuration parameters can only be accessed when the steering system is
in non-automatic (NFU/Standby or FU/Helm) steering mode. The configuration parameters are protected by
access codes to prevent unauthorized changes to the parameters.
To modify the software configuration parameters, refer to Appendix A (Configuration Data) for instructions.
3.5 ALARM/STATUS RELAYS.
The NAVIPILOT 4000 SCU provides alarm and status indications via five single-pole double-throw relays. For
each relay, the normally closed (NC), normally open (NO), and common (Com) contacts are interfaced to TB1 of
the SCU (see Figure 3-1).
The SYSTEM ALARM relay is energized when no unacknowledged alarm exists in the system, and de-energized
when an unacknowledged alarm exists. The relay contacts are pins 79 (NC), 80 (NO), and 81 (Com).
The functions of the other four relays are configured at installation when performing the SCU configuration
settings (Service Setup 2), as described in Appendix A. Table 3-5 lists the relays, and defines the option for each
configuration. In each case, the relay is energized when the selected alarm or status signal is active.
Table 3-5. Software-Configurable Alarm Relays

SCU Nomenclature Terminals Choices Description
RELAY 1
OVERRIDE ALARM NC 34 None No function assigned to relay.
(default setting: Override) NO 35
Com 36 Override Steering control has been overridden by an
external device. (See section 2.4 for details.)
Ext Sys Active The system is in EXTERNAL steering mode
using an analog input from a system such as
a Dynamic Positioning System (DPS).
NOTE: When the Ext Sys Active function is
configured, and the system is in external
steering mode:
In software releases R and later, the relay
will remain actuated if an Override
condition occurs.
In software releases P and earlier, the
relay will be de-actuated if an Override
condition occurs.
G/M Advisor The heading source selected is magnetic.

Auto The system is in automatic steering mode
(AUTO), or AUTO is being overridden.
Off Hdg Alarm An Off Heading alarm condition exists.
Deadman Contact Produces a one-second pulse at each
operator interaction (when the system is
operated in FU mode, and the operator
pushes any button or causes movement of
the helm wheel).
3-18 JA19-8039F

Helm Advisor A Helm Wheel Not Zeroed condition exists.
(The helm wheel has been moved from the
center position at least 5 degrees for ten
seconds.)
Mute Produces a one-second pulse when the
operator acknowledges an alarm.
Hdg Difference A Heading Difference alarm condition exists.
Nav Mode The NAVIPILOT 4000 is in the Nav mode of
operation. Refer to Section 2.6.2 for a
description of this mode.
Track Mode The NAVIPILOT 4000 is in the Track mode of
RELAY 2
MODE STATUS (default NC 73 None No function assigned to relay.
setting: Auto) NO 74
Com 75 Override Steering control has been overridden by an
Ext Sys Active The system is in external steering mode using
an analog input from a system such as a
DPS.
the helm wheel).
Helm Advisor A Helm Wheel Not Zeroed fault exists. (The
helm wheel has been moved from the center
position at least 5 degrees for ten seconds.)
Hdg Difference A Heading Difference alarm condition exists.
JA19-8039F 3-19
NAVIPILOT 4000

RELAY 3
OFF COURSE ALARM NC 76 Off Hdg Alarm An Off Heading alarm condition exists.
(default setting: Off Hdg NO 77
Alarm) Com 78
RELAY 4
DEADMAN CONTACT NC 82 None No function assigned to relay.
(default setting: Deadman NO 83
Contact) Com 84 Override Steering control has been overridden by an
Ext Sys Active The system is in external steering mode using
an analog input from a system such as a
DPS.
the helm wheel).
Helm Advisor A Helm Wheel Not Zeroed fault exists. (The
helm wheel has been moved from the center
position by at least 5 degrees for ten
seconds.)
Hdg Difference The difference between the heading values
from any two heading sources is greater the
operator-selected limit (1 to 15 degrees).
3-20 JA19-8039F
3.6 CONNECTING TO A VOYAGE DATA RECORDER (VDR).
The RS-422 VDR output provides the NMEA 0183 (Version 2.3) Rudder Sensor Angle (RSA) and Heading Track
Control Data (HTD) serial messages. For instructions on connecting the NAVIPILOT 4000 to a VDR, contact
Sperry Marine.
3.7 CONNECTING TO THE NAV CHANNEL
The RS-422 NAV channel provides bi-directional serial communication with an external track control device. For
instructions on connecting to the NAV channel of the NAVIPILOT 4000, contact Sperry Marine.
3.8 USING AN EXTERNAL INPUT WITH A MECHANICAL MODE SWITCH (MMS)
In systems using a Mechanical Mode Switch (MMS) (see Table 1-5), the conventional steering modes (NFU,
Helm, Auto, Remote) are selected by connecting the appropriate mode pin (49 52) to input pin 53. The
NAVIPILOT 4000 is also capable of using a +/- 10V input as the steering order from an external system. This
external steering mode is engaged by using the switch to connect input pins 51 and 52 to pin 53.
3.9 HELM UNIT CALIBRATION
3.9.1 Helm Unit Calibration Procedure (for Systems with Software Prior to Revision U)
The autopilot allows the operator to calibrate the zero point of an analog input by setting the input to zero. The
operator then chooses a gradient that is used on either side of this point.
To calibrate the helm unit:
1. Confirm that all connections from the steering control system to the steering gear system are correct and
secure, and that all mechanical steering gear adjustments have been made.
2. Enter all known configuration parameters (see Appendix A).
3. From the Service Setup 2 SCU CONFIGURATION SETTINGS menu (Table A-4), select ANALOG
INTERFACE.
4. From the ANALOG INTERFACE menu, select HELM.
5. When the HELM ENABLED prompt appears, press YES. The HELM menu appears.
6. From the HELM menu, select MAXIMUM ANGLE, and enter the desired value for the maximum
rudder angle.
7. Zero the helm (helm at amidships).
8. Zero the helm potentiometer.
9. From the HELM menu, select CALIBRATION.
10. From the CALIBRATION menu, select ZERO HELM and press OK.
11. Determine the helm gradient value as follows:
JA19-8039F 3-21
NAVIPILOT 4000
a. Position the helm wheel to some order near the extremes of rudder travel. Note the helm
pointer location in degrees.
b. Using a voltmeter, measure and note the DC voltage between Steering Control Unit
terminals TB1-72 (CT) and TB1-70 (W).
c. Divide the DC voltage (in millivolts) by the helm pointer location (in degrees). This is the
helm gradient value, in millivolts per degree.
12. From the CALIBRATION menu:
c. Select HELM GRADIENT.
d. Enter the helm gradient value determined in step 11, and press ACCEPT.
3.9.2 Helm Unit Calibration Procedure (for Systems with Revision U Software or Later)
The multiport (3 to 7 point) calibration procedure for helm feedback is performed by following the instructions
provided on the display. All of the SCU's are calibrated at the same time, and each SCU gets its own calibration
values. When performing the calibration procedure, some of the calibration points may be skipped. The system
will allow the calibration procedure to be completed if at least one PORT position is calibrated, one STARBOARD
position is calibrated, and the ZERO position is calibrated (3 points minimum). Up to 7 positions may be
calibrated, but only 3 positions are required. The calibration positions are automatically selected based on the
maximum calibration angle. For example, if "45 degrees" is the maximum calibration angle, the system will select
"45 degrees port", the "30 degrees port", "15 degrees port", 0 degrees", "15 degrees stbd", "30 degrees stbd",
and "45 degrees stbd" as the calibration positions. During the calibration process, the CDU will display in real-
time the voltage from each SCU of the port that is being calibrated.
To calibrate the helm unit:
1. Confirm that all connections from the steering control system to the steering gear system are correct and
secure, and that all mechanical steering gear adjustments have been made.
3. From the Service Setup 2 SCU CONFIGURATION SETTINGS menu (Table A-4), select ANALOG
INTERFACE.
4. From the ANALOG INTERFACE menu, select HELM.
5. When the HELM ENABLED prompt appears, press YES. The HELM menu appears.
6. From the HELM menu, select MAXIMUM CAL ANGLE, and enter the desired value for the maximum
rudder angle.
7. Zero the helm (helm at amidships).
8. Zero the helm potentiometer.
9. From the HELM menu, select CALIBRATE.
10. From the CALIBRATE menu, follow the instructions on the display to perform the 7 point calibration
procedure for the helm. Press OK after performing each step.
3-22 JA19-8039F
3.10 RUDDER REPEATBACK (FEEDBACK) CALIBRATION OR ZEROING
If the rudder repeatback (feedback) input is used, calibrate this input using the procedure in paragraphs 3.10.1
and 3.10.2. If rudder repeatback (feedback) is not used, zero the input using the procedure in paragraph 3.10.3.
3.10.1 Calibration Procedure (for Systems with Software Prior to Revision U)
To calibrate the rudder repeatback (feedback) input:
1. Confirm that all connections from the steering control system to the steering gear system are
correct and secure, and that all mechanical steering gear adjustments have been made.
3. From the Service Setup 2 SCU CONFIGURATION SETTINGS menu (Table A-4), select
ANALOG INTERFACE.
4. From the ANALOG INTERFACE menu, select FEEDBACK.
5. When the FEEDBACK ENABLED prompt appears, press YES. The FEEDBACK menu appears.
6. From the FEEDBACK menu:
a. Select MAXIMUM ANGLE.
b. Enter the maximum rudder angle, and then press ACCEPT.
7. Use the NFU device to place the rudder at zero degrees.
8. Zero the feedback potentiometer.
9. From the FEEDBACK menu, select CALIBRATION.
10. From the CALIBRATION menu, select ZERO FEEDBACK, and then press OK.
11. Determine the feedback gradient value, as follows:
a. Using the NFU controller or some other method of manually moving the rudder, place the
rudder at hardover position.
b. Note the rudder travel in degrees.
c. Using a voltmeter, measure and note the DC voltage between SCU terminals TB1-67 (CT)
and TB1-65 (W).
d. Divide the DC voltage (in millivolts) by the rudder travel (in degrees). This is the feedback
gradient value, in millivolts per degree.
12. From the CALIBRATION menu:
a. Select FEEDBACK GRADIENT.
b. Enter the feedback gradient value determined in step 11, and press ACCEPT.
JA19-8039F 3-23
NAVIPILOT 4000
3.10.2 Calibration Procedure (for Systems with Revision U Software or Later)

The multiport (3 to 7 point) calibration procedure for rudder feedback is performed by following the instructions
provided on the display. All of the SCU's are calibrated at the same time, and each SCU gets its own calibration
values. When performing the calibration procedure, some of the calibration points may be skipped. The system
will allow the calibration procedure to be completed if at least one PORT position is calibrated, one STARBOARD
position is calibrated, and the ZERO position is calibrated (3 points minimum). Up to 7 positions may be
calibrated, but only 3 positions are required. The calibration positions are automatically selected based on the
maximum calibration angle. For example, if "45 degrees" is the maximum calibration angle, the system will select
"45 degrees port", the "30 degrees port", "15 degrees port", 0 degrees", "15 degrees stbd", "30 degrees stbd",
and "45 degrees stbd" as the calibration positions. During the calibration process, the CDU will display in real-
time the voltage from each SCU of the port that is being calibrated.
To calibrate the rudder repeatback (feedback) input:
1. Confirm that all connections from the steering control system to the steering gear system are
correct and secure, and that all mechanical steering gear adjustments have been made.
ANALOG INTERFACE.
6. From the FEEDBACK menu:
a. Select MAXIMUM CAL ANGLE.
b. Enter the maximum rudder angle, and then press ACCEPT.
7. Use the NFU device to place the rudder at zero degrees.
8. Zero the feedback potentiometer.
9. From the FEEDBACK menu, select CALIBRATE.
10. From the CALIBRATE menu, follow the instructions on the display to perform the 7 point
calibration procedure. Press OK after performing each step.
3-24 JA19-8039F
3.10.3 Zeroing Procedure
To zero the rudder repeatback (feedback) input (if rudder repeatback is not used):
ANALOG INTERFACE.
4. From the FEEDBACK menu, select ZERO FEEDBACK, and then select OK.
5. Return to the ANALOG INTERFACE menu, and select FEEDBACK.
6. When the FEEDBACK ENABLED prompt appears, press NO.
3.11 CONFIGURING A SIDE MASTER/SIDE SLAVE RUDDER REPEATBACK (RRB) INTERFACE
The following description is applicable to NAVIPILOT 4000 software versions R and later.
Refer to Figure 3-11. For systems in which two SCUs control the same rudder, the two SCUs can be configured
for Side Master/Side Slave interface of the rudder repeatback (RRB) signal. When this configuration is used:
The analog RRB signal from the rudders repeatback unit is supplied to the REPEATBACK input of
both SCUs (pins 64 - 67).
An RS-422 interface is used for digital communication of RRB data from one SCU to the other:
e. Each SCU transmits digital RRB data via its CENTRAL ALARM RS422 output (pin 42: TD+;
pin 43: TD-).
f. Each SCU receives digital RRB data via its SPARE RS422 input (pin 21: RD+; pin 22: RD-).
g. Data format is as follows: 38.4k baud, 8 data bits, 1 stop bit, no handshaking.
The RRB Side Master is the SCU which is controlling the pump(s) that are actuating the rudder. The
other SCU functions as the RRB Side Slave. (Therefore, the SCU that functions as the RRB Side
Master is not necessarily the system Master.)
The Side Master SCU uses its analog RRB input as its source for RRB information, and supplies
digital RRB data to the Side Slave via the RS-422 interface. The Side Slave SCU uses the digital
RRB messages from the Side Master, and ignores its own analog RRB input.
If the RS-422 interface fails, the Side Slave SCU will automatically use its analog RRB input as its
source for RRB information.
In a quad SCU system (with two rudders and two SCUs per rudder), the two port SCUs are connected as shown
in Figure 3-11, and the two starboard SCUs are connected as shown in Figure 3-11. Each pair of SCUs operates
as described above.
JA19-8039F 3-25
NAVIPILOT 4000
RRB
Side Master/
Side Slave
SCU No. 1 Interface SCU No. 2
CENTRAL TD+ 42 21 RD+

ALARM SPARE
RS422 TD- 43 22 RD- RS422
RD+ 21 CENTRAL
SPARE 42 TD+
ALARM
RS422 RD- 22 43 TD- RS422
REPEATBACK REPEATBACK
+12V W -12V CT +12V W -12V CT
64 65 66 67 64 65 66 67
RRB unit
Rudder
Figure 3-11. Rudder Repeatback (RRB) Interfaces - Side Master/Side Slave Configuration
Appendix A contains the specific procedures for configuring the SCU software for RRB Side Master/Side Slave
operation. General guidelines are as follows:
1. In the SCU CONFIGURATION - SERIAL INTERFACE - CENTRAL ALARM INTERFACE menu, the
CENTRAL ALARM RS-422 port can be set for Central Alarm Manager interface (CAM ONLY), or
for RRB interface (RRB ONLY). The port must be set to RRB ONLY for RRB Side Master/Side
Slave operation. (If a CAM interface is also desired, the SCUs NAV port can be configured for
CAM interface via the SCU CONFIGURATION - SERIAL INTERFACE - CENTRAL ALARM
INTERFACE ON VMS PORT menu.)
2. In the SCU CONFIGURATION - STEERING GEAR - SIDE SLAVE RRB SOURCE menu, Side
Master/Side Slave operation is enabled when both SCUs are set to MASTER. Side Master/Side
Slave operation is disabled when both SCUs are set to OWN.
3-26 JA19-8039F
3.12 INITIAL TUNING
If the Adaptive Self-Tuning feature of the NAVIPILOT 4000 is enabled, an initial tuning sequence should be
performed during sea trials, or as soon as possible after the vessel goes to sea. Refer to Chapter 2, section 2.18
for initial tuning sequence instructions.
3.13 RESTORING SCU CONFIGURATION DEFAULTS
Should the need arise, the capability exists for the field service engineer to restore the factory default SCU
configuration. Whenever it is necessary to reset an SCU, all SCUs in the system should be reset. To restore the
SCU default configuration:
1. Verify that the CDU is communicating with the SCU. (The SCU NOT RESPONDING message in
inverse video is NOT displayed on the CDU.)
2. Select a non-automatic mode of operation (NFU, Standby, etc.) by using the systems mode switch,
or by jumpering pins 59 and 60.
3. Select the Service Setup 2 configuration menus, and enter the appropriate access code, in
accordance with the instructions in Appendix A.
4. At the Service Setup 2 menus:
a. Configure the SCU/Main Mode Switch to MMS.
b. Configure SCU/Ports to their respective default modes, as listed below. Do not set any port
configuration to NONE.
Port Configuration
PORT 1 NFU NFU or STANDBY
PORT 2 FU FU or HELM
PORT 3 AUTO AUTO
PORT 4 RMT REMOTE
5. Exit the configuration menus, allowing the new configuration to be saved.
6. Power off the system.
7. At TB1 of the SCU, jumper pins 49, 50, 51, 52, and 53 together.
8. Power the system(s) on, and leave the system(s) on for at least 10 seconds.
9. Power off the system(s), and remove the jumper(s).
10. Re-install the proper mode input connector, and power the system(s) on.
11. Configure the Service Setup 1 and Service Setup 2 parameters as desired, in accordance with the
instructions in Appendix A.
JA19-8039F 3-27
NAVIPILOT 4000
This operation to restore a default configuration is only for the SCU. The CDU is not affected. When
communication with the SCU is not possible, you can modify only the CDU settings by performing the following
procedure:
1. Simultaneously press MENU, soft key 3 (the third of the four keys below the display), and DIM+.
2. Press SERVICE SETUP 2, and enter the access code.
3-28 JA19-8039F
Chapter 4 Alarm System
CHAPTER 4
ALARM SYSTEM
4.1 POWER-UP SELF TEST
During power-up, the NAVIPILOT 4000 performs a self-test. After the self-test, the system beeps once and
presents the following start-up screen:
SPERRY MARINE
HEADING CONTROL SYSTEM
DISPLAY: XXXXXXX
PORT 1 XXXXXXX
Only SCUs present are shown.
PORT 2 XXXXXXX
XXXXXXX indicates the
STBD 1 XXXXXXX software part number.
STBD 2 XXXXXXX
SYSTEM STARTUP
JA19-8039F 4-1
NAVIPILOT 4000
4.2 ALARM DISPLAY AND ACKNOWLEDGMENT.
When the NAVIPILOT detects a new fault or alarm condition, the CDU will display ALARM and generate an
audible tone. The ALARM indication is displayed in alternating normal and reverse video until the alarm is
acknowledged. To display and acknowledge an alarm:
Press the MENU button, then press ALARM LIST. Depending on configuration, it may be
necessary to press the MENU button several times to access the ALARM LIST choice.
When the list is displayed, press the ACK soft key to acknowledge the alarms and silence the audible
tone. Press the > soft key to see if multiple faults exist. If all alarms and faults have been cleared,
the list will display No Faults as soon as ACK is pressed, and the ALARM indication will no longer
be displayed at the CDU. If a fault or alarm condition still exists, the ALARM indication remains
steadily displayed in reverse video. Select EXIT to return to the previous menu.
To quickly mute a new alarm or fault, the user can press the ACCEPT button. However, if the fault or
alarm has already been cleared internally, a description of the alarm cannot be viewed after pressing
ACCEPT. If the fault still exists, the description can be viewed as described above.
NOTE: The ACCEPT button is also used to accept preset course changes. If a fault occurs
while a preset course change is pending, the first press of ACCEPT will mute the fault/alarm.
The user must press ACCEPT again after the fault/alarm is muted, in order to execute the
preset course change.
4-2 JA19-8039F
4.3 FAULT CODES.
Table 4-1 lists the fault codes that may appear on the NAVIPILOT 4000.
Table 4-1. Fault Codes

Fault
Description Comments Corrective Action
No.
0 NO FAULT No faults were detected.
1 PARSE FAULT Serial message parse fault. Check cables.
2 PARITY ERROR Serial message parity error. Check cables.
3 FRAMING ERROR Serial message framing error. Check cables.
4 SERIAL ERROR Serial message general error. Check cables.
5 APB MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
6 HTR MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
7 HSC MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
8 XTE MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
9 HTC MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
10 PROP HTC MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
11 CTS MSG MISSING NMEA message missing. Verify that navigator is operating.
Check cables.
12 VBW MSG MISSING NMEA message missing. Verify that speed log is operating.
Check cables.
13 VHW MSG MISSING NMEA message missing. Verify that speed log is operating.
Check cables.
14 VTG MSG MISSING NMEA message missing. Verify that speed log is operating.
Check cables.
15 HDT 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
16 HEHDT 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
17 HCHDT 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
18 HDG 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
19 HDM 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
JA19-8039F 4-3
NAVIPILOT 4000

Fault
No.
20 NSD 1 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
21 HDT 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
22 HEHDT 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
23 HCHDT 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
24 HDG 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
25 HDM 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
26 NSD 2 MSG MISSING NMEA message missing. Verify that compass is operating.
Check cables.
27 APB CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
navigator for proper operation.
28 HTR CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
29 HSC CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
30 XTE CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
31 HTC CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
32 PROP HTC CHECKSUM NMEA message missing. Invalid navigator data. Check
FAULT navigator for proper operation.
33 CTS CHECKSUM FAULT NMEA message missing. Invalid navigator data. Check
34 VBW CHECKSUM FAULT NMEA message missing. Invalid speed log data. Check
speed log for proper operation.
35 VHW CHECKSUM FAULT NMEA message missing. Invalid speed log data. Check
36 VTG CHECKSUM FAULT NMEA message missing. Invalid speed log data. Check
37 HDT 1 CHECKSUM FAULT NMEA message missing. Invalid compass data. Check
compass for proper operation.
38 HEHDT 1 CHECKSUM NMEA message missing. Invalid compass data. Check
FAULT compass for proper operation.
39 HCHDT 1 CHECKSUM NMEA message missing. Invalid compass data. Check
40 HDG 1 CHECKSUM NMEA message missing. Invalid compass data. Check
4-4 JA19-8039F

Fault
No.
41 HDM 1 CHECKSUM NMEA message missing. Invalid compass data. Check
42 NSD 1 CHECKSUM FAULT NMEA message missing. Invalid compass data. Check
43 HDT 2 CHECKSUM FAULT NMEA message missing. Invalid compass data. Check
44 HEHDT 2 CHECKSUM NMEA message missing. Invalid compass data. Check
45 HCHDT 2 CHECKSUM NMEA message missing. Invalid compass data. Check
46 HDG 2 CHECKSUM NMEA message missing. Invalid compass data. Check
47 HDM 2 CHECKSUM NMEA message missing. Invalid compass data. Check
48 NSD 2 CHECKSUM FAULT NMEA message missing. Invalid compass data. Check
49 APB PARSE FAULT NMEA message missing. Check navigator for proper
operation.
50 HTR PARSE FAULT NMEA message missing. Check navigator for proper
operation.
51 HSC PARSE FAULT NMEA message missing. Check navigator for proper
operation.
52 XTE PARSE FAULT NMEA message missing. Check navigator for proper
operation.
53 HTC PARSE FAULT NMEA message missing. Check navigator for proper
operation.
54 PROP HTC PARSE FAULT NMEA message missing. Check navigator for proper
operation.
55 CTS PARSE FAULT NMEA message missing. Check navigator for proper
operation.
56 VBW PARSE FAULT NMEA message missing. Check speed log for proper
operation.
57 VHW PARSE FAULT NMEA message missing. Check speed log for proper
operation.
58 VTG PARSE FAULT NMEA message missing. Check speed log for proper
operation.
59 HDT 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
60 HEHDT 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
61 HCHDT 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
JA19-8039F 4-5
NAVIPILOT 4000

Fault
No.
62 HDG 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
63 HDM 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
64 NSD 1 PARSE FAULT NMEA message missing. Check compass for proper
operation.
65 HDT 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
66 HEHDT 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
67 HCHDT 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
68 HDG 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
69 HDM 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
70 NSD 2 PARSE FAULT NMEA message missing. Check compass for proper
operation.
71 APB DATA FAULT NMEA message missing. Check navigator or track data
source for proper operation.
72 XTE DATA FAULT NMEA message missing. Check navigator or track data
73 XTRCK DATA FAULT NMEA message missing. Check navigator or track data
74 TRK BEAR DATA FAULT NMEA message missing. Check navigator or track data
75 HD STEER DATA FAULT NMEA message missing. Check navigator or track data
76 TURN RATE DATA FAULT NMEA message missing. Check navigator or track data
77 OVERRIDE DATA FAULT NMEA message missing. Check navigator or track data
78 RUD ORD DATA FAULT NMEA message missing. Check navigator or track data
79 STEER MODE DATA NMEA message missing. Check navigator or track data
FAULT source for proper operation.
80 TURN MODE DATA NMEA message missing. Check navigator or track data
FAULT source for proper operation.
81 RUD LIM DATA FAULT NMEA message missing. Check navigator or track data
82 OFF CRS DATA FAULT NMEA message missing. Check navigator or track data
4-6 JA19-8039F

Fault
No.
83 TURN RAD DATA FAULT NMEA message missing. Check navigator or track data
84 OFF TRK DATA FAULT NMEA message missing. Check navigator or track data
85 HEAD REF DATA FAULT NMEA message missing. Check navigator or track data
86 W SPD DATA FAULT NMEA message missing. Check speed log for proper
operation.
87 B SPD DATA FAULT NMEA message missing. Check speed log for proper
operation.
88 HDG GYRO DATA NMEA message missing. Check compass for proper
FAULT 1 operation.
89 HDG MAG DATA FAULT 1 NMEA message missing. Check compass for proper
operation.
90 HDG SRC DATA FAULT 1 NMEA message missing. Check compass for proper
operation.
91 HDG GYRO DATA NMEA message missing. Check compass for proper
FAULT 2 operation.
92 HDG MAG DATA FAULT 2 NMEA message missing. Check compass for proper
operation.
93 HDG SRC DATA FAULT 2 NMEA message missing. Check compass for proper
operation.
94 HEADING 1 RATE FAULT --- Check compass for proper
operation.
operation.
operation.
97 FLUXGATE VOLTAGE --- Check compass for proper
FAULT operation.
98 SPEED RANGE FAULT --- Check speed log for proper
operation.
99 BOTTOM SPD RANGE --- Check speed log for proper
FAULT operation.
100 CONTROL CHECKSUM Some or all of the configuration data Perform Service Setup 1 and 2
FAULT has been corrupted or reset to its (see Appendix A).
default values.
101 INVALID MAC ADDRESS --- EPROM Failure in SCU or CDU.
102 CONFIG DATABASE INIT Some or all of the configuration data Perform Service Setup 1 and 2
FAULT has been corrupted or reset to its (see Appendix A).
default values.
JA19-8039F 4-7
NAVIPILOT 4000

Fault
No.
103 DISPLAY FAULT FOR --- ---
TEST
104 SPEED LOG LOST Serial speed lost. Verify speed log for proper
operation. Check cables.
105 CONTROLLING STATION Steering station in control not Select new steering device.
LOST responding.
106 STATION NOT Desired steering station refused Select new steering device.
ACCEPTED CONTROL control.
107 ORDER LOST FAULT The expected heading order Verify navigator or track data for
message (APB, HSC, HTC, CTS) proper operation.
was not received within 15 seconds.
108 ORDER FORMAT FAULT The message format does not Verify navigator or track data for
match the NMEA 0183 format. proper operation.
109 ORDER INVALID FAULT The heading order data field is null Verify navigator or track data for
or the validity field is set to invalid. proper operation.
110 ORDER RANGE FAULT The raw heading order is greater Verify navigator or track data for
than 360.0 or less than 000.0 for proper operation.
3 seconds.
111 RATE LOST FAULT The expected heading rate order Verify navigator or track data for
message (HTR) is not received proper operation.
within 15 seconds.
112 RATE FORMAT FAULT The message format does not Verify navigator or track data for
match the NMEA 0183 format. proper operation.
113 RATE INVALID FAULT The rate order data field is null or Verify navigator or track data for
the validity field is set to invalid. proper operation.
114 RATE RANGE FAULT The raw rate order is greater than Verify navigator or track data for
twice the configured maximum turn proper operation.
rate or less than 0 for 3 seconds.
115 TRACK DATA LOST The expected cross track error Verify navigator or track data for
FAULT message (APB, XTE) is not proper operation.
received within 15 seconds.
116 TRACK DATA FORMAT The message format does not Verify navigator or track data for
FAULT match the NMEA 0183 format. proper operation.
117 TRACK DATA INVALID The cross-track error data field is Verify navigator or track data for
FAULT null, or the validity field is set to proper operation.
invalid.
118 PROM CHECKSUM ---
FAULT
119 RAM READ WRITE FAULT ---
120 NVRAM CHECKSUM --- Perform service setup 1 and 2.

FAULT
121 CONFIGURATION --- Perform service setup 1 and 2.
STORAGE
4-8 JA19-8039F

Fault
No.
122 CONTROL STORAGE --- Perform service setup 1 and 2.
123 SERIAL EEPROM ---

STORAGE
124 HELM WHEEL NOT Helm wheel has been moved from Zero the helm wheel.
ZEROED center position at least 5 degrees
for 10 seconds.
125 HELM UNIT NOT --- Calibrate helm unit.
CALIBRATED
126 RRB NOT CALIBRATED --- Calibrate rudder repeatback.
127 EXTERNAL UNIT NOT --- Calibrate the external unit.

CALIBRATED
128 JOYSTICK IO FAULT --- Future enhancement.
129 JOYSTICK NOT --- Future enhancement.

CENTERED
130 MODE SWITCH IO Mode switch in invalid position. Check mode switch.
131 DIAGNOSTIC PORT --- Future enhancement.
132 ABS OVERRIDE Activated ABS override function. Check helm wheel position.
When enabled, ABS Override
activates if helm wheel position is
greater than configured setting for
2 seconds.
133 GYRO COMPASS 1 LOST --- Check compass.
134 MAG COMPASS 1 LOST --- Check compass.
135 GYRO COMPASS 2 LOST --- Check compass.
136 MAG COMPASS 2 LOST --- Check compass.
137 ALARM NOT RECEIVED --- Future enhancement.
138 SPEED LOG RANGE 200P/NM input. Check speed log.

FAULT
139 --- --- ---
140 TRACK HDG ERROR Operator advisory message. Check track.

EXCEEDED
141 OFF COURSE FAULT Operator advisory message. Check course.
JA19-8039F 4-9
NAVIPILOT 4000

Fault
No.
142 COMPASS SELECTED --- Check compass selection.
NOT CONFIGURED
143 NO STATION IN --- Select a steering station.
CONTROL
144 HEADING DIFF LIM Heading difference limit exceeded. Check compass.
EXCEEDED
145 OFF TRACK FAULT --- Check track.
146 GENERAL DEVICE FAULT This is an all-purpose alarm for the Check bus interface unit.
Bus Interface Units (BIUs). (Table
1-5 lists the various types of BIUs.)
147 GENERAL BIU fault indicating inconsistencies Reconfigure affected BIU.
CONFIGURATION FAULT in the setup.
148 ELECTRIC SHAFT Follow-Up Miniwheel/Display Unit Check Follow-Up Miniwheel/
TIMEOUT motor cannot be moved. Display Unit.
149 WHEEL POSITION Follow-Up Miniwheel/Display Unit Check Follow-Up Miniwheel/
INVALID wheel position not reliable. Display Unit.
150 DISPLAY CONTROLLER General Bus Interface Unit (BIU) Check BIU.
ERROR display error.
151 STATION NOT AVAILABLE The selected station cannot come Select new steering station.
into control.
152 USE LOG SPEED FOR The NAVIPILOT 4000 cannot Change to log speed.
RADIUS TURNS perform accurate rate control turns
without a speed log input.
153 NAV MODE NOT Nav mode is not configured. Check navigator configuration.
AVAILABLE
154 TRACK MODE NOT Track mode is not configured. Check track controller
AVAILABLE configuration.
155 AUTO DISABLED, HDG The heading source used for Switch to manual mode and select
SRC SELECTED LOST steering is lost switch to manual another compass or repair lost
steering. compass.
156 NAV CRS CHG GREATER NAV mode course change is greater Verify that the course change is
THAN 15 DEG than 15 degrees. This alarm is appropriate.
generated only if NAV ACK is
enabled in the SERVICE SETUP 2 -
SCU CONFIGURATION menu, and
the HTC message is available.
157 TRACK CRS CHG TRACK mode course change is Verify that the course change is
GREATER THAN 15 DEG greater than 15 degrees. This appropriate.
alarm is generated only if TRACK
ACK is enabled in the SERVICE
SETUP 2 - SCU CONFIGURATION
menu, and the HTC message is
available.
4-10 JA19-8039F

Fault
No.
158 LOST PORT SCU UNIT 1 Slave SCU times out in 30 seconds Reboot PORT SCU UNIT 1 if SCU
and never clears the fault. does not clear itself.
159 LOST PORT SCU UNIT 2 Slave SCU times out in 30 seconds Reboot PORT SCU UNIT 2 if SCU
160 LOST STBD SCU UNIT 1 Slave SCU times out in 30 seconds Reboot STBD SCU UNIT 1 if SCU
161 LOST STBD SCU UNIT 2 Slave SCU times out in 30 seconds Reboot STBD SCU UNIT 2 if SCU
162 RAM FAULT RAM test failed. Turn unit off and back on. If fault
does not clear, contact Sperry
Marine.
163 ROM FAULT ROM test failed. Turn unit off and back on. If fault
does not clear, contact Sperry
Marine.
164 POWER RESTORED IN Operator advisory message. The Acknowledge alarm.
AN AUTOMATIC MODE NAVIPILOT 4000 was powered up
in AUTO mode.
165 Not used -- --
166 PSMI VMS STEERING The system has been configured to Confirm that the interface to the
MODE MSG MISSING receive the "$PSMI,STEERING VMS is configured properly and
MODE" message, but is not that the VMS is outputting this
receiving this message from the message.
VMS.
167 PSMI VMS STEERING Steering mode message checksum Confirm that the format of the
MODE CHECKSUM is invalid. message being sent is correct.
FAULT
168 PSMI VMS STEERING Steering mode message format is Confirm that the format of the
MODE PARSE FAULT invalid. message being sent is correct.
169 NAV ALERT: TRACK System has stopped VMS NAV Check communications with NAV
CONTROL STOPPED (TRACK CONTROL) mode. (VMS) system.
170 TRACK CONTROL NAV (VMS) system has forced Check NAV system for the reason.
FAILURE: CHECK NAV system to downgrade to AUTO
SYSTEM mode.
171 HEADING SOURCE The heading source changed while Do not allow the heading source to
CHANGED IN AUTO the system was in an automatic change while the system is in
mode. AUTO, NAV, or TRACK mode.
JA19-8039F 4-11
NAVIPILOT 4000

Fault
No.
172 CAN BUS ERROR This alarm is not posted on the Refer to CAN bus documentation.
display, but is output via the CAM
interface and the RS-232 diagnostic
interface, to provide status on CAN
Bus errors. CAN BUS ERROR 0 0
will be output for a normally
functioning CAN bus. Non-zero
values will be output if CAN bus
errors are detected.
173 RATE TURN SELECTED The NAVIPILOT 4000 has Avoid using radius orders near the
FOR PRESENT SPEED automatically changed the turn allowable maximum.
method from RADIUS to RATE,
Increase speed in order to
because RADIUS turns are not
complete the turn at the desired
allowed at the current speed. The
radius, or continue to use the
TURN METHOD indicator flashes
RATE turn method.
(in addition to the ALARM indicator)
until the alarm is acknowledged.
174 RATE TURN SELECTED The NAVIPILOT 4000 has Avoid using radius orders near the
FOR PRESENT TAU automatically changed the turn expected maximum if there is a
method from RADIUS to RATE, significant change in loading.
because Tau has changed (due to a
Increase speed in order to
loading change) such that the turn
complete the turn at the desired
radius exceeded the allowable
radius, or continue to use the
maximum. The TURN METHOD
RATE turn method.
indicator flashes (in addition to the
ALARM indicator) until the alarm is
acknowledged.
175 RATE ORDER The NAVIPILOT 4000 has Avoid using rate orders near the
INCREASED FOR automatically increased the RATE expected minimum if there is a
PRESENT TAU order, because Tau has changed significant change in loading, or
(due to a loading change) such that use the RUDDER LIMIT turn
the turn radius was below the method.
allowable minimum. The TURN
METHOD indicator flashes (in
addition to the ALARM indicator)
until the alarm is acknowledged.
176 RAD ORDER The NAVIPILOT 4000 has Increase speed in order to
DECREASED FOR automatically decreased the complete the turn at the desired
PRESENT SPEED RADIUS order, because the turn radius, or use the RATE turn
radius exceeded the allowable method.
maximum for the current speed.
The TURN METHOD indicator
flashes (in addition to the ALARM
indicator) until the alarm is
acknowledged.
177- Not used --- ---
186
4-12 JA19-8039F

Fault
No.
187 RRB RS-422 ERROR Rudder repeatback Side Master/ Determine whether the RRB Side
Side Slave interface error. Master/Side Slave interface has
been correctly configured (see
Chapter 3 and Appendix A).
Check for continuity on the RS-422
connection between each Side
Master and its Side Slave.
188 CDU/SCU PORT 1 Indicates a software mismatch Select the SERVICE SETUP 2
MISMATCH between the CDU and Port SCU menu, and check the CDU and
No. 1. SCU software revision letters on
the MAIN SERVICE SETUP menu.
(see Appendix A). If a mismatch
does exist, contact Sperry Marine
for the necessary firmware.
189 CDU/SCU PORT 2 Indicates a software mismatch Select the SERVICE SETUP 2
MISMATCH between the CDU and Port SCU menu, and check the CDU and
No. 2. SCU software revision letters on
190 CDU/SCU STBD 1 Indicates a software mismatch Select the SERVICE SETUP 2
MISMATCH between the CDU and Starboard menu, and check the CDU and
SCU No. 1. SCU software revision letters on
191 CDU/SCU STBD 2 Indicates a software mismatch Select the SERVICE SETUP 2
MISMATCH between the CDU and Starboard menu, and check the CDU and
SCU No. 2. SCU software revision letters on
192 MINIWHEEL OVERRIDE Steering control has been Verify that the operator of the FMW
overridden by actuation of a did not inadvertently override
Follow-up Mini-Wheel (FMW). steering control.
193 EXTERNAL OVERRIDE Steering control has been Verify that the operator of the
overridden by actuation of an external device did not
external device (other than a inadvertently override steering
Follow-up Mini-Wheel). control.
JA19-8039F 4-13
NAVIPILOT 4000
THIS PAGE LEFT BLANK
4-14 JA19-8039F
Chapter 5 Diagnostics
CHAPTER 5
DIAGNOSTICS
5.1 DIAGNOSTIC LED INDICATORS
Tables 5-1 through 5-3 list the diagnostic LED indicators on the Control and Display Unit (CDU), the Steering
Control Unit (SCU), the AC Solenoid Interface PCB, and the DC Solenoid Interface PCB. Prior to replacing the
CDU or SCU, observe the LEDs to determine the suspect unit.
Table 5-1. Control and Display Unit (CDU) Diagnostic LEDs
Reference
Color Function
Designation
DS1 Green When flashing (at an approximately 1Hz rate), indicates that the CPU is operational.
DS2 Green When on, indicates that the +5V logic supply is present. (The LED will light if the
supply is at least +2V).
DS3 Red When flashing, indicates CAN bus traffic. If the LED is continuously on, a CAN bus
problem is indicated.
Table 5-2. Steering Control Unit (SCU) Diagnostic LEDs
Reference
Color Function
Designation
DS1 Green When flashing (at an approximately 1Hz rate), indicates that the CPU is operational.
DS2 Green When on, indicates that the +5V logic supply is present. (The LED will light if the
supply is at least +2V).
DS3 Red When flashing, indicates message activity on the SPEED RS422 serial input
channel.
DS4 Red When flashing, indicates message activity on the HEADING 1 RS422 serial input
channel.
DS5 Red When flashing, indicates message activity on the HEADING 2 RS422 serial input
channel.
DS6 Red When flashing, indicates activity on the SPEED 200P/NM input.
DS7 Red When on, indicates activation of the Non-Follow-Up (NFU) input. (This input is
labeled MSU/NFU in earlier configurations; SMN/NFU in later configurations.)
DS8 Red When on, indicates that the MODE switch input is set to NFU.
DS9 Red When on, indicates that the MODE switch input is set to HELM.
JA19-8039F 5-1
NAVIPILOT 4000
Table 5-2. Steering Control Unit (SCU) Diagnostic LEDs
Reference
Color Function
Designation
DS10 Red When on, indicates that the MODE switch input is set to AUTO.
DS11 Red When on, indicates that the MODE switch input is set to REMOTE.
DS12 Red When flashing, indicates message activity on the SPARE RS422 serial input
channel.
DS13 Red When flashing, indicates message activity on the NAV RS422 serial input channel.
DS14 Red When flashing, indicates message activity on the CENTRAL ALARM RS422 serial
input channel.
DS17 thru -- Not used.

DS20
DS21 Red When on, indicates that the OVERRIDE switch closure input is activated.
DS22 Red When on, indicates that the SPARE switch closure input is activated.
DS23 Green When on, indicates that the -12V supply is present. (The LED will light if the supply
is at least -2V).
DS24 Green When on, indicates that the +12V supply is present. (The LED will light if the supply
is at least +2V).
Table 5-3. AC or DC Solenoid Interface PCB Diagnostic LEDs
Reference
Color Function
Designation
DS1 Red When on, indicates that the PUMP 1 LEFT output is active.
DS2 Red When on, indicates that the PUMP 1 RIGHT output is active.
DS3 Red When on, indicates that the PUMP 2 LEFT (or DUMP) output is active.
DS4 Red When on, indicates that the PUMP 2 RIGHT output is active.
NOTE: The Pump 1 solenoid interface can only be configured for operation of a directional valve. The Pump 2
solenoid interface can be configured for operation of a directional or dump valve. Refer to Chapter 3 and
Appendix A for details.
5-2 JA19-8039F
Appendix A Configuration Data
APPENDIX A
CONFIGURATION DATA
A.1 RUDDER GAIN (RG) AND COUNTER RUDDER (CR) OPERATIONAL SETTINGS.
Use Table A-1 to record the manually entered rudder gain (RG) and counter rudder (CR) values which are found
to provide the best steering performance during sea trials. See chapter 2 for instructions for entering the gains
manually.
NOTE: The Medium load condition is available only if the NAVIPILOT 4000s Adaptive Self-Tuning feature is not
enabled (that is, when the SYS TYPE in Service Setup 2 is set to either PID or PID/MST). Service Setup 2
configuration settings are described in section A.3.2 of this appendix.
Table A-1. User Settings for Rudder Gain (RG) and Counter Rudder (CR)
Rudder Gain Counter Rudder

Load Remarks
(RG) (CR)
Light
Medium
Loaded
JA19-8039F A-1
NAVIPILOT 4000
A.2 MAGNETIC FLUXGATE COMPASS CALIBRATION.
The Magnetic Fluxgate Compass Calibration function compensates for minor differences that occur between the
magnetic fluxgate compass heading and the heading data transmitted by the gyrocompass. To perform this
function, the maintenance technician enters correction factors for storage in the NAVIPILOT 4000 memory, using
the SERVICE SETUP 1 menu.
NOTE: This calibration method is only used when the fluxgate compass is connected directly to the
NAVIPILOT 4000 SCU. When a fluxgate compass is connected via a Navitwin III compass monitor unit,
the calibration must be performed at the Navitwin III, which then provides the fluxgate heading to
NAVIPILOT 4000 as serial data.
To enter the calibration data:

a. Verify that the magnetic fluxgate compass has been properly installed and calibrated, and set the correct
magnetic variation for the geographic location. (Refer to Chapter 2 for instructions).
b. Select the manual steering mode.
c. Press MENU until the SERVICE SETUP 1 configuration menu appears. Select SERVICE SETUP 1.
d. Enter the access code for SERVICE SETUP 1. (Contact Sperry Marine for access codes.)
e. Select FLUXGATE CAL TABLE, and press the ACCEPT soft key.
f. Select SET UP CALIBRATION from the CALIBRATE FLUXGATE screen, and press the ACCEPT soft
key.
g. Select CALIBRATE from the CALIBRATE FLUXGATE START screen, and press the ACCEPT soft key.
h. Operate the helm wheel until the heading indication on the magnetic fluxgate compass is 000.
i. Record the gyrocompass heading indication in Table A-2.
j. Calculate the required correction value for each heading. Record the calculated value in Table A-2.
Example: The actual magnetic fluxgate compass heading is 010. The actual gyrocompass
heading is 011. The required correction value is 1.
k. Press the (up) or (down) soft key until the calculated value is displayed. Press the ACCEPT soft key.
l. Repeat steps h through k for each of the magnetic fluxgate compass headings listed in Table A-2.
A-2 JA19-8039F
Table A-2. Magnetic Fluxgate Compass Calibration Table
Magnetic Magnetic
Fluxgate Gyrocompass Correction Fluxgate Gyrocompass Correction
Compass Heading Value Compass Heading Value
Heading Heading
000 ___________ __________ 180 __________ ___________
010 ___________ __________ 190 __________ ___________
020 ___________ __________ 200 __________ ___________
030 ___________ __________ 210 __________ ___________
040 ___________ __________ 220 __________ ___________
050 ___________ __________ 230 __________ ___________
060 ___________ __________ 240 __________ ___________
070 ___________ __________ 250 __________ ___________
080 ___________ __________ 260 __________ ___________
090 ___________ __________ 270 __________ ___________
100 ___________ __________ 280 __________ ___________
110 ___________ __________ 290 __________ ___________
120 ___________ __________ 300 __________ ___________
130 ___________ __________ 310 __________ ___________
140 ___________ __________ 320 __________ ___________
150 ___________ __________ 330 __________ ___________
160 ___________ __________ 340 __________ ___________
170 ___________ __________ 350 __________ ___________
JA19-8039F A-3
NAVIPILOT 4000
A.3 CONFIGURATION SETTINGS
Maintenance personnel can configure the NAVIPILOT 4000 for a variety of operating modes and Heading Control
System configurations, by using the SERVICE SETUP 1 and SERVICE SETUP 2 menus as described below.
IMPORTANT:
If all SCUs are powered on and communicating on the NAVINET 4000 Steering Control Network,
the setup procedures described below will configure all SCUs simultaneously. Otherwise, the
installer must repeat the configuration procedure each time a new SCU is powered on. The same
configuration settings must be entered at each SCU to ensure consistent system performance and
capabilities, regardless of which SCU is in use.
For the configuration settings to take effect, the NAVIPILOT 4000 MUST be powered off and
powered up again after completing service setup.
A.3.1 Configuration Settings SERVICE SETUP 1.

To enter the SERVICE SETUP 1 configuration settings:
a. Select a non-automatic steering mode (follow-up or non follow-up).
b. Power-on all SCUs.
c. At a CDU, press MENU until the SERVICE SETUP 1 soft key appears. Press the SERVICE SETUP 1
soft key.
d. Enter the access code for SERVICE SETUP 1. (Refer to the latest Field Engineering Bulletin.)
e. From the SERVICE SETUP 1 menu, select HCS CONFIGURATION, and press the ACCEPT soft key.
f. Table A-3 lists each of the HCS CONFIGURATION parameters. Make the appropriate selections, and
record the configuration settings in the table.
g. Press the EXIT key to exit the HCS CONFIGURATION menu.
h. Press the EXIT key again to exit the SERVICE SETUP 1 menu. The selected configuration settings will
be stored in the NAVIPILOT 4000 memory.
A.3.2 Configuration Settings SERVICE SETUP 2.
To enter the SERVICE SETUP 2 configuration settings:

a. Select a non-automatic steering mode (follow-up or non follow-up).
b. Power-on all SCUs.
c. At a CDU, press MENU until the SERVICE SETUP 2 soft key appears. Press the SERVICE SETUP 2
soft key.
d. Enter the access code for SERVICE SETUP 2. (Refer to the latest Field Engineering Bulletin.)
e. At the MAIN SERVICE SETUP menu (Figure A-1), verify that all SCUs are reporting their part number
and revision, and that the part numbers and revisions are all the same. (Figure A-1 shows a two-SCU
configuration, with the SCUs identified as PORT 1 and STBD 1.)
f. To enter the SCU configuration settings:
1) From the MAIN SERVICE SETUP menu, select SCU CONFIGURATION, then press the ACCEPT
soft key.
2) Table A-4 lists each of the SCU CONFIGURATION parameters. Make the appropriate selections,
and record the configuration settings in the table.
A-4 JA19-8039F
3) Press the EXIT key to exit the SCU CONFIGURATION menu.

g. To enter the CDU configuration settings:
1) From the MAIN SERVICE SETUP menu, select CDU CONFIGURATION, then press the ACCEPT
soft key.
2) Table A-5 lists each of the CDU CONFIGURATION parameters. Make the appropriate selections,
3) Press the EXIT key to exit the CDU CONFIGURATION menu.
4) If there are additional CDUs to be configured in the Heading Control System, repeat steps c, d, and
g for each CDU. Verify that all CDU part numbers and revisions are the same. (Figure A-1 shows
a single-CDU configuration, with the CDU identified as DISPLAY.)
h. To enter the SYS configuration settings:
1) From the MAIN SERVICE SETUP menu, select SYS CONFIGURATION, then press the ACCEPT
soft key.
2) Table A-6 lists each of the SYS CONFIGURATION parameters. Make the appropriate selections,
3) Press the EXIT key to exit the SYS CONFIGURATION menu.
i. Press the EXIT key again to exit the MAIN SERVICE SETUP menu. The selected configuration settings
will be stored in the NAVIPILOT 4000 memory.
Figure A-1. Typical MAIN SERVICE SETUP Menu
JA19-8039F A-5
NAVIPILOT 4000
Table A-3. Service Setup 1 HCS Configuration Settings
Item Configuration Setting Function
NOTE: In the Tau, RG, and CR load settings below, the MEDIUM load condition is not available to the
user if the Adaptive Self-Tuning feature is enabled. Refer to SYS Configuration (Table A-6).
TAU:
Sets the ships time constant (tau) for each load

condition setting. Tau is the time in seconds it takes
TAU LIGHT _____________ sec.
for the ship to traverse a distance of its own length at
TAU MEDIUM _____________ sec. service (cruising) speed. Ship length is defined as
the length at the waterline, or the length between
TAU LOADED _____________ sec.
perpendiculars. See Appendix B for formulas.
Range: 1 to 80 seconds. Default: 20 seconds.
SERVICE SPEED:
Sets the ships service (cruising) speed. Range: 5 to

SERV SPD ______________ kn.
35 knots. Default: 20 knots.
RG INIT:
RG LIGHT _________________ Sets the initial rudder gain for each load condition
setting. Also, if Adaptive Self-Tuning is enabled, the
RG MEDIUM _________________
rudder gain is reset to these initial values if RESET
RG LOADED _________________ TUNING is performed. Range: 0.3 to 3.0. Default: 1.4.
CR INIT:
Sets the initial counter rudder gain for each load

CR LIGHT _________________
condition setting. Also, if Adaptive Self-Tuning is
CR MEDIUM _________________ enabled, the counter rudder gain is reset to these
initial values if RESET TUNING is performed. Range:
CR LOADED _________________
0.3 to 3.0. Default: 1.0.
OVERRIDE RECOVERY:
These settings dictate how the system responds when an override is cancelled by selecting PREV MODE
(Previous Mode) at an ancillary unit. Default settings are recommended. These settings have no effect if the
override capability is not available in the system.
When an override is cancelled by selecting PREV

MODE:
ACT HDG (Actual Heading) The set heading will
be the same as the current actual heading, and
ACT HDG (default) the vessel will remain on its current course.
HEADING
LAST ORD LAST ORD (Last Order) The previous heading
order will go into effect. This may result in a
significant change to set heading, depending on
how far the vessel deviated from the previous
order. In this mode, the override may be used to
jog around an obstruction.
A-6 JA19-8039F
Table A-3. Service Setup 1 HCS Configuration Settings (continued)
When an override is cancelled by selecting PREV

MODE:
AUTO The system will drop from Nav or Track to
AUTO (default) Auto mode. The user must take deliberate steps to
MODE resume Nav or Track mode after an override.
A/N/T
A/N/T (Auto/Nav/Track) the system will truly
revert to the previous mode when PREV MODE is
selected, including Nav or Track if the override
occurred in either of those modes.
CROSS TRACK:
These settings are only used when the NAV interface uses APB or HSC/XTE messages for Track mode at the
NAVIPILOT 4000.
Sets the amount of heading correction to make based

XT ERROR GAIN ____________ /nm on cross-track error. Range: 2 to 280 degrees per
nautical mile. Default: 50/nm.
Sets the amount of heading correction to make based

XT RATE GAIN ______________/kn on cross-track error rate. Range: 0.0 to 5.0 degrees
per knot. Default: 0.0/kn.
XT APPROACH ANGLE Sets the maximum angle for regaining the track.
________________
LIM Range: 20 to 60 degrees. Default: 20 degrees.
Sets the time constant used to calculate cross-track

XT FILTER TC _____________ sec rate. Range: 10 to 180 seconds. Default: 30
seconds.
YES (default) Allows the bias calculation to be disabled for tuning

XT BIAS ENABLE
NO the track controller.
Sets the time constant used in the bias calculation.

XT BIAS TC _____________ sec
Range: 50 to 500 seconds. Default: 300 seconds.
Speed Scaled Rudder Limit (SSRL):
Sets the maximum rudder angle allowed at service

SS RUD ________________ speed. Range: 5 to 45 degrees. Default: 20
degrees.
NOTE: The Speed Scaled Rudder Limit applies regardless of set rudder limit or rate/radius order. The selected
limit is scaled to other speeds. For example, if the SSRL is set to 20 degrees, with a service speed of 20 kn:
At 30 kn, the SSRL would stop the rudder at approximately 13 degrees.
At 15 kn, the SSRL would allow approximately 27 degrees rudder.
JA19-8039F A-7
NAVIPILOT 4000
Table A-4. Service Setup 2 SCU Configuration Settings
SERIAL INTERFACE:
HEADING 1:
Determines the NMEA message type for a

Gyrocompass input at the HDG 1 port in the
NONE
SCU:
GYRO HDT
HDT - True Heading
HEHDT (default)
HEHDT - North-Seeking Gyro, True
Heading

Magnetic Heading input at the HDG 1 port:
HCHDT - Mag. Compass, True Heading
HDG - Heading, Deviation, and Variation
NONE (default) HDM - Magnetic Heading
HCHDT WARNING: Do NOT configure a NMEA
MAGNETIC
HDG message for a magnetic compass when a
HDM fluxgate compass is configured. Such a
configuration error will cause the NAVIPILOT
4000 to toggle between the NMEA heading data
and the heading data from the fluxgate
compass, when magnetic is selected as the
heading source.
YES Sets up the HDG 1 port to receive the serial

NSD NSD (Navigation Status Data) message, from a
NO (default) connected Navitwin II compass monitor.
1200
2400
4800 (default)
9600
BAUD RATE Sets the Baud Rate for HDG 1.
14.4
19.2
28.8
38.4
HEADING 2:

Gyrocompass input at the HDG 2 port in the
NONE
SCU:
GYRO HDT
HDT - True Heading
HEHDT (default)
HEHDT - North-Seeking Gyro, True
Heading
A-8 JA19-8039F
Table A-4. Service Setup 2 SCU Configuration Settings (continued)

Magnetic Heading input at the HDG 2 port:
HCHDT - Mag. Compass, True Heading
HDG - Heading, Deviation, and Variation
NONE (default) HDM - Magnetic Heading
HCHDT WARNING: Do NOT configure a NMEA
MAGNETIC
HDG message for a magnetic compass when a
HDM fluxgate compass is configured. Such a
configuration error will cause the NAVIPILOT
4000 to toggle between the NMEA heading data
and the heading data from the fluxgate
compass, when magnetic is selected as the
heading source.
YES Sets up the HDG 2 port to receive the serial

NSD NSD message, from a connected Navitwin III
NO (default) compass monitor.
1200
2400
4800 (default)
9600
BAUD RATE Sets the Baud Rate for HDG 2.
14.4
19.2
28.8
38.4
JA19-8039F A-9
NAVIPILOT 4000
SPEED:
Sets the speed message type:

None
VTG (Course Over Ground and Ground
Speed)
NONE
VBW (Dual Ground/Water Speed)
VHW
MESSAGE TYPE VTG 200 pulses per nautical mile, triggered on
(software releases R the rising edge of the pulse (+)
and later) VBW (default)
200P/NM + 200 pulses per nautical mile, triggered on
the falling edge of the pulse (-)
200P/NM -
For a VBW message, water speed has
preference. Ground speed is used when water
speed is not available.
For a 200P/NM input, if the speed display is
erratic with one of the two selections (+ or -),
use the other selection.
Sets the speed message type:

None
NONE
VHW VTG (Course Over Ground and Ground
MESSAGE TYPE
Speed)
(software releases P VTG
and earlier) VBW (default) VBW (Dual Ground/Water Speed)
200P/NM 200 pulses per nautical mile
For a VBW speed message, water speed has
preference. Ground speed is used when water
speed is not available.
1200
2400
4800 (default)
9600 Sets the Baud Rate expected for the Speed
BAUD RATE
14.4 message.
19.2
28.8
38.4
A-10 JA19-8039F
NAV INTERFACE:
Sets the NMEA message used for the Nav

interface:
If the Nav interface is not used, select
NONE.
NONE (default) For interface to a Sperry Marine Voyage
APB Management System (VMS)/NAVIECDIS,
APB, HTR select HSC, PROP-HTC, HTR (Heading to
Steer Command, Proprietary Heading To
HSC
Complete, Heading Turn Rate). This will
HSC, HTR enable NAV mode operation of the
MESSAGE TYPE HSC, XTE NAVIPILOT 4000.
HSC, XTE, HTR For interface to a GPS or a compatible
HSC, PROP-HTC, HTR non-Sperry chart system, select APB
HTC (Heading/Track Controller [Autopilot]
Sentence B) or HSC/XTE (Heading-to-
HTC, XTE
Steer Command/Cross-Track Error), as
CTS appropriate for the system being used. This
will enable TRACK mode operation of the
NAVIPILOT 4000.
The remaining choices are not valid and
should not be used.
1200
2400
4800 (default)
9600
BAUD RATE Sets the Baud Rate used for the Nav interface.
14.4
19.2
28.8
38.4
Determines the Set Heading to be used if

communications are lost to the navigator during
a VMS-controlled turn in NAV mode:
RES HDG Resume on Heading. The
current heading at the time that
RES HDG (default) communications are lost becomes the set
LOST NAV
COMPL TURN heading.
COMPL TURN Complete the Turn. The
bearing of the next leg of the turn becomes
the set heading. Use this mode on DNV
Watch 1 vessels, and on other vessels when
required.
JA19-8039F A-11
NAVIPILOT 4000
YES Sets an alarm when TRACK mode course

TRACK ACK
NO (default) change is >15 degrees.
YES Sets an alarm when NAV mode course change

NAV ACK
NO (default) is >15 degrees.
YES
NAV STATUS MSG Standby in non-master status.
NO (default)
Selects whether the Nav Steering Mode

Message from a Sperry VMS is used. This
message is available only in commercial
VMS/NAVIECDIS 7.0 or later.
NAV STEERING YES
MODE MSG NO (default) If YES is selected, the VMS will automatically
switch the NAVIPILOT 4000 from NAV mode to
AUTO mode if a system failure makes NAV
mode unavailable (such as loss of the
necessary sensor data.)
5 (default) Sets the duration at which the Nav Steering

NAV MSG TIMEOUT 10 Mode Message timeout alarm is triggered, in
15 seconds.
REPEATER INTERFACE:
YES
REPEATER ENABLED Enables or disables the Serial Repeater.
NO (default)
4800 (default) Determines the Baud Rate output through the
BAUD RATE
9600 Serial Repeater channel.
CENTRAL ALARM INTERFACE (software releases R and later):
Selects the function of the Central Alarm port:

OFF (default) Off
CENTRAL ALARM
CAM ONLY Central Alarm Manager (CAM) interface
PORT
RRB ONLY 38.4
RRB Side Master/Slave interface
(38.4k baud rate)
4800 (default)
9600 If CAM ONLY is selected above, sets the baud
BAUD RATE
19.2 K rate for the Central Alarm Manager interface.
38.4 K
CENTRAL ALARM INTERFACE (software releases P and earlier):
CENTRAL ALARM YES Enables or disables the Central Alarm Manager

ENABLED NO (default) (CAM) interface.
A-12 JA19-8039F
4800 (default)
BAUD RATE Sets the baud rate for the CAM interface.
9600
CENTRAL ALARM INTERFACE ON VMS PORT:
Select YES to echo Central Alarm Manager

(CAM) messages on the NAV interface port.
This configuration is used when:
YES More than one output of CAM messages is

ECHO TO VMS PORT required, or
NO (default)
A CAM interface is required, but the Central
Alarm Interface is configured for Rudder
Repeatback (RRB 38.4) Side Master/Slave
interface only.
ANALOG INTERFACE:
HELM:
YES
HELM ENABLED Selects whether a helm analog input is used.
NO (default)
MAXIMUM ANGLE Sets the maximum helm rudder angle. Range:

_________________ .
(NOTE 2) 20 to 120 degrees. Default: 35 degrees.
MAXIMUM CAL Sets the maximum helm rudder angle. Range:

_________________ .
ANGLE (Note 1) 20 to 120 degrees, in 1 degree increments.
PORT HELM OK
PORT HELM OK
PORT HELM OK
CALIBRATE (Note 1) ZERO HELM OK Sets the points for the 7 point calibration.
STBD HELM OK
STBD HELM OK
STBD HELM OK
CALIBRATION:
ZERO HELM Calibrates the NAVIPILOT 4000 to read the

OK current setting of the helm control as zero
(Note 2) degrees when OK is selected.
HELM GRADIENT Sets the voltage scaling of the helm analog

______________ mV/. input. Range: 100 to 350 mV/degree. Default:
(Note 2) 250 mV/degree.
Note 1 Calibration procedure used with Revision U software or later.
Note 2 Calibration procedure used prior to the release of Revision U software.
JA19-8039F A-13
NAVIPILOT 4000
FEEDBACK:
YES Enables or disables the rudder repeat-back
FEEDBACK ENABLED
NO (default) function.
MAXIMUM ANGLE Sets the maximum rudder repeat-back

_________________ . angle. Range: 20 to 120 degrees. Default:
(Note 2) 35 degrees.
Sets the maximum helm rudder angle.

MAXIMUM CAL ANGLE
_________________ . Range: 20 to 120 degrees, in 1 degree
(Note 1)
increments.
PORT HELM OK
PORT HELM OK
PORT HELM OK
CALIBRATE (Note 1) ZERO HELM OK Sets the points for the 7 point calibration.
STBD HELM OK
STBD HELM OK
STBD HELM OK
CALIBRATION:
ZERO FEEDBACK Calibrates the NAVIPILOT 4000 to read the

OK current input from the rudder repeat-back
(Note 2) as zero degrees when OK is selected.
FEEDBACK GRADIENT Sets the voltage scaling of the analog

_____________ mV/. rudder repeat-back. Range: 100 to 350
(Note 2) millivolts per degree. Default: 250 mV/.
EXTERNAL SYSTEM:
YES Selects whether an external system input is
EXTERNAL ENABLED
NO (default) used.
Sets the maximum external system rudder

MAXIMUM ANGLE _________________ . angle. Range: 20 to 120 degrees. Default:
35 degrees.
STBD POS (default)

POLARITY Sets the steering gear voltage polarity.
PORT POS
CALIBRATION:
Calibrates the NAVIPILOT 4000 to read the

ZERO EXTERNAL OK current input from the external system as
zero degrees when OK is selected.
Note 2 Calibration procedure used prior to the release of Revision U software
A-14 JA19-8039F
Sets the voltage scaling of the external system

EXTERNAL
______________ mV/. input. Range: 100 to 350 millivolts per degree.
GRADIENT
Default: 250 mV/.
FLUXGATE:
Enables or disables fluxgate compass interface.

YES Select YES only when a fluxgate compass is
FLUXGATE
NO (default) installed and connected using the SCU fluxgate
ports.
PORTS:
MODE PORTS (PINS 49-53):
Assigns the name to be displayed on the CDU

STANDBY when Port 1 is selected. This mode is selected
PORT 1 NFU
NFU (default) using SCU Pin 49, or by a switch that closes
pins 59/60.
NONE
HELM
FU (default)
Assigns a function to Port 2 (SCU Pin 50).
G/M
Normally FU or HELM is selected, and the
180 OFFSET GYRO 1 name displayed on CDU will be either FU or
PORT 2 FU 180 OFFSET GYRO 2 HELM depending on selection. The functions
180 OFFSET MAG 180 PORT, 180 STBD, and EN JOYSTICK have
not yet been implemented in the NAVIPILOT
180 PORT
4000 software, and will not function if selected.
180 STBD
EN JOYSTICK
MUTE
NONE
AUTO (default)
G/M
180 OFFSET GYRO 1 Normally AUTO is selected, unless the system
180 OFFSET GYRO 2 is main steering only. The functions 180 PORT,
PORT 3 AUTO
180 OFFSET MAG 180 STBD, and EN JOYSTICK have not yet
180 PORT been implemented in the NAVIPILOT 4000
software, and will not function if selected.
180 STBD
EN JOYSTICK
MUTE
JA19-8039F A-15
NAVIPILOT 4000
NONE
REMOTE (default)
G/M
180 OFFSET GYRO 1 Normally REMOTE is selected, if the system
180 OFFSET GYRO 2 includes remote locations. The functions 180
PORT 4 RMT
180 OFFSET MAG PORT, 180 STBD, and EN JOYSTICK have not
180 PORT yet been implemented in the NAVIPILOT 4000
software, and will not function if selected.
180 STBD
EN JOYSTICK
MUTE
NONE (default)
DPS
AUTO
Sets the name to be displayed on the CDU
BACK_UP when External mode has been selected. When
EXTERNAL SYSTEM
PILOT a mechanical mode switch is used, SCU Pins
NAME
TRACK 51 & 52 must be connected to select External
mode.
RADAR
CHART
AUX
JOYSTICK PORTS (PINS 54-58):
NONE (default)
JOY UP
G/M
180 OFFSET GYRO 1 Assigns a function to Joystick Port 1. The
180 OFFSET GYRO 2 functions JOY UP, 180 PORT, 180 STBD, and
PORT 1 UP EN JOYSTICK have not yet been implemented
180 OFFSET MAG in the NAVIPILOT 4000 software, and will not
180 PORT function if selected.
180 STBD
EN JOYSTICK
MUTE
NONE (default)
JOY DOWN
G/M
PORT 2 DOWN EN JOYSTICK have not yet been implemented
180 STBD
EN JOYSTICK
MUTE
A-16 JA19-8039F
NONE (default)
JOY RIGHT
G/M
PORT 3 RIGHT EN JOYSTICK have not yet been implemented
180 STBD
EN JOYSTICK
MUTE
NONE (default)
JOY LEFT
G/M
PORT 4 LEFT EN JOYSTICK have yet not been implemented
180 STBD
EN JOYSTICK
MUTE
JA19-8039F A-17
NAVIPILOT 4000
OVERRIDE ACTIVE IN:
For any device which indicates override of

steering control via a contact closure at the
SCUs OVERRIDE input (pins 32 and 33), the
NAVIPILOT 4000 will allow override by that
device in the configured operating mode(s):
None
AUTO, NAV, and TRACK
EXTERNAL
NONE
FU (Follow-Up)
AUTO/NAV/TRACK
EXT SYSTEM AUTO, NAV, TRACK, and EXTERNAL
FU SYSTEM AUTO, NAV, TRACK, and FU
OVERRIDE ACTIVE IN
A/N/T/E AUTO, NAV, TRACK, EXTERNAL, and FU
A/N/T/FU (default) EXTERNAL and FU
A/N/T/E/FU
For a Sperry Marine Follow-Up Mini-Wheel
EXT SYST/FU (FMW), which indicates override of steering
control via the CAN bus:
Override capability must be enabled at the
FMW. Otherwise, it cannot override
steering control in any mode.
If override capability is enabled at the
FMW, the FMW can override steering
control in the configured modes, with the
exception of FU.
RELAYS:
NONE
OFF HDG ALARM
HDG DIFFERENCE
OVERRIDE (default)
DEADMAN CONTACT
EXT SYS ACTIVE
RELAY 1 (TB 34-36) Assigns a function to Relay 1.
HELM ADVISOR
G/M ADVISOR
MUTE
AUTO (W/ OVR)
NAV MODE
TRACK MODE
A-18 JA19-8039F
NONE
OFF HDG ALARM
HDG DIFFERENCE
OVERRIDE
DEADMAN CONTACT
EXT SYS ACTIVE
RELAY 2 (TB 73-75) HELM ADVISOR Assigns a function to Relay 2.
G/M ADVISOR
MUTE
AUTO (W/ OVR)
(default)
NAV MODE
TRACK MODE
Assigns a function to Relay 3. (Off Heading

RELAY 3 (TB 76-78) OFF HDG ALARM
alarm is always assigned.)
NONE
OFF HDG ALARM
HDG DIFFERENCE
OVERRIDE
DEADMAN CONTACT
(default)
RELAY 4 (TB 82-84) EXT SYS ACTIVE Assigns a function to Relay 4.
HELM ADVISOR
G/M ADVISOR
MUTE
AUTO (W/ OVR)
NAV MODE
TRACK MODE
STEERING GEAR:
MAXIMUM RUDDER:
Sets the maximum rudder angle in NAVIPILOT

4000 steering mode. Range: 5 to 120 degrees.
MAX RUD _________________ . Default: 35 degrees. NOTE: Counter Rudder
(CR) limit is 45 degrees or the MAX RUD
setting, whichever is smaller.
JA19-8039F A-19
NAVIPILOT 4000
STAGING THRESHOLDS:
STAGE 1:
Rudder error at which the solenoid for Stage 1 activates.

ON __________________.
Range: 0.1 to 7.3 degrees. Default: 0.8 degrees.
Rudder error at which the solenoid for Stage 1 de-

OFF __________________. activates. Range: 0.0 to 7.2 degrees. Default: 0.5
degrees.
STAGE 2: (Note 1)

ON __________________.
STAGE 3: (Note 1)

ON __________________.
STAGE 4: (Note 1)

ON __________________.
STAGE 5: (Note 1)

ON __________________.
STAGE 6: (Note 1)

ON __________________.
STAGE 7: (Note 1)

ON __________________.
STAGE 8: (Note 1)

ON __________________.
A-20 JA19-8039F
ANALOG OUTPUT:
Sets the analog output as proportional to the

PRO (default) rudder order (PRO) or as proportional to the
MODE
PRE rudder error (PRE). PRO is selected in most
cases.
STBD POS (default)

POLARITY Sets the steering gear voltage polarity.
PORT POS
Sets the voltage scaling of the steering gear

analog output. Range: 80 to 350 millivolts per
CALIBRATION ______________ mV/.
degree (PRO); 500 to 2000 mV/ (PRE).
Default: 250 mV/ (PRO); 1000 mV/ (PRE).
AC SOLENOID BOARD 1:
PUMP 1:
STAGE 1 (default) Determines which stage of hydraulic flow control

SCU 1 for a directional valve is performed by the Pump
STAGE 2 1 section of AC solenoid board 1 in SCU 1.
STAGE 1 Determines which stage of hydraulic flow control

STAGE 2 (default) 1 section of AC solenoid board 1 in SCU 2.
OFF (default) Determines whether the pump status (Pump

STATUS On) signal is used by the Pump 1 section of AC
PUMP STAT solenoid board 1.
PUMP 2:
STAGE 1 (default)
STAGE 2
for a directional or dump valve is performed by
SCU 1 STAGE 4
the Pump 2 section of AC solenoid board 1 in
DUMP 2 SCU 1.
DUMP 3
DUMP 4
STAGE 1
STAGE 2 (default)
SCU 2 STAGE 4
DUMP 2 SCU 2.
DUMP 3
DUMP 4
JA19-8039F A-21
NAVIPILOT 4000

AC SOLENOID BOARD 2:
PUMP 1:

STAGE 2 1 section of AC solenoid board 2 in SCU 1.

STAGE 2 (default) 1 section of AC solenoid board 2 in SCU 2.

PUMP 2:
STAGE 1 (default)
STAGE 2
SCU 1 STAGE 4
DUMP 2 SCU 1.
DUMP 3
DUMP 4
STAGE 1
STAGE 2 (default)
SCU 2 STAGE 4
DUMP 2 SCU 2.
DUMP 3
DUMP 4

DC SOLENOID BOARD 1:
PUMP 1:

STAGE 2 1 section of DC solenoid board 1 in SCU 1.
A-22 JA19-8039F

STAGE 2 (default) 1 section of DC solenoid board 1 in SCU 2.

STATUS On) signal is used by the Pump 1 section of DC
PUMP 2:
STAGE 1 (default)
STAGE 2
SCU 1 STAGE 4
the Pump 2 section of DC solenoid board 1 in
DUMP 2 SCU 1.
DUMP 3
DUMP 4
STAGE 1
STAGE 2 (default)
SCU 2 STAGE 4
DUMP 2 SCU 2.
DUMP 3
DUMP 4

DC SOLENOID BOARD 2:
PUMP 1:

STAGE 2 1 section of DC solenoid board 2 in SCU 1.

STAGE 2 (default) 1 section of DC solenoid board 2 in SCU 2.

JA19-8039F A-23
NAVIPILOT 4000
PUMP 2:
STAGE 1 (default)
STAGE 2
SCU 1 STAGE 4
DUMP 2 SCU 1.
DUMP 3
DUMP 4
STAGE 1
STAGE 2 (default)
SCU 2 STAGE 4
DUMP 2 SCU 2.
DUMP 3
DUMP 4

SIDE SLAVE RRB (RUDDER REPEATBACK) SOURCE (software releases R and later):
For system configurations in which two SCUs

control the same rudder, and the digital RRB
Side Master/Slave interface between the two
SCUs is enabled:
Select MASTER at both SCUs to enable
the Side Master/Slave RRB configuration.
The Side Master SCU will use its analog
RRB input as its RRB source. The Side
Slave will use the digital RRB messages
from the Side Master SCU, and ignore its
OWN (default) analog RRB input.
SIDE SLAVE RRB
SOURCE MASTER Select OWN at both SCUs to disable the
Side Master/Slave RRB configuration.
Each SCU will use its analog RRB input as
its RRB source, and ignore the digital RRB
messages from one SCU to the other.
Press the ACCEPT softkey to accept the OWN
or MASTER selection; press the CANCEL key
to cancel the selection.
For system configurations in which a single
SCU controls a rudder, the configuration setting
has no effect.
A-24 JA19-8039F
ABS OVERRIDE:
Enables or disables ABS Override. If YES is

selected, the main helm wheel will override
Auto/Nav/Track modes when the wheel is
NO (default) moved from the center position by a configured
ABS OVERRIDE
YES value for more than two seconds.
NOTE: ABS Override is normally not enabled
unless required by the inspecting agency.
If YES is selected above, allows input of the

setting at which movement of the main helm
ABS OVER _________________ . wheel from the center position will override
Auto/Nav/Track modes. Range: 3 to 8 degrees.
Default: 5 degrees.
HELM ADVISOR:
Enables or disables the Helm Advisor function.

If enabled, an alarm is generated if the main
YES helm wheel is moved from the zero position
HELM ADVISOR while in an automatic steering mode.
NO (default)
NOTE: Helm Advisor should not be enabled if
ABS override is enabled.
SERVICE INTERFACE:
2400
4800
BAUD RATE Sets the Baud Rate for the service interface.
9600 (default)
19200
NONE (default)
PARITY EVEN Sets the Parity for the service interface.
ODD
7 Sets the Data Width for the service interface
DATA WIDTH
8 (default) (future enhancement).
1 (default) Sets the Stop Bits for the service interface

STOP BITS
2 (future enhancement).
CAN INTERFACE:
SIGNAL RATE 250K (default) Sets the CAN baud rate.
JA19-8039F A-25
NAVIPILOT 4000
MAIN MODE SWITCH:
Selects the type of main mode selection switch

NONE installed:
MODE SWITCH MMS (default) MMS = Mechanical Mode Switch
SMS SMS = Steering Mode Selector (a Bus
Interface Unit)
ALARM CONDITIONS:
DEADMAN ALARM DISABLE (default) Enables or disables alarm for no operator

TIMEOUT ENABLE response.
If ENABLE is selected above, allows input of the

duration after which a Deadman alarm will
DEAD TIME ______________ sec.
occur. Range: 1 to 253 seconds. Default: 5
seconds
When ENABLE is selected, the operator menu

for OFF HEADING LIMIT allows selection of
OFF as an option. When OFF is selected from
OFF HEADING ALARM ENABLE that menu, the Off Heading alarm is disabled.
DISABLE DISABLE (default)
When DISABLE is selected, the OFF HEADING
LIMIT operator menu does not allow the
operator to disable the Off Heading alarm.
Sets the delay time for the external Off Heading

OFF HEADING DELAY ______________ sec. alarm. Range: 0 to 40 seconds. Default:
1 second.
Sets the minimum speed attainable without an

MINIMUM SPEED _______________ kn.
alarm. Range: 1 to 10 knots. Default: 2 knots.
Sets the maximum speed attainable without an

MAXIMUM SPEED _______________ kn. alarm. Range: 1 to 99 knots. Default:
40 knots.
Sets the conditions under which an alarm is

generated if steering control is overridden by a
Follow-Up Mini-Wheel or other external device:
NONE None
OVERRIDE ALARM FMW Override by Follow-up Mini-Wheel
(software releases R and
later) EXT Override by other external device, as
FMW+EXT (default) indicated by a contact-closure at the SCUs
OVERRIDE input (pins 32 and 33).
Override by Follow-up Mini-Wheel or other
external device
A-26 JA19-8039F
Table A-5. Service Setup 2 CDU Configuration Settings
LOCATION:
4: MAIN (default)
5: PORT WING
6: STBD WING
7: NAVSTATION
8: HELMSMAN STATION
9: MANEUVERING STATION
10: AFT BRIDGE Identifies the control location associated
LOCATION
11: FORWARD BRIDGE with the device.
12: EMERGENCY STATION
13: FLY BRIDGE
14: PORT FLYBRIDGE
15: STBD FLYBRIDGE
________________
[16 thru 31]
NAME:
4: MAIN (default)
5: PORT WING
6: STBD WING
7: NAVSTATION
8: HELMSMAN STATION
9: MANEUVERING STATION
10: AFT BRIDGE Identifies the display title associated with
NAME
11: FORWARD BRIDGE the device.
12: EMERGENCY STATION
13: FLY BRIDGE
14: PORT FLYBRIDGE
15: STBD FLYBRIDGE
________________
[16 thru 255]
AUDIBLE OVERRIDE:
ALL
OVERRIDE Beeps when an override condition occurs.
A/N/T (default)
TENTH TIMEOUT:
Sets the duration of time following the last

TENTH TIME ______________ sec. Set Heading change. Range: 10 to 60
seconds. Default: 10 seconds.
JA19-8039F A-27
NAVIPILOT 4000
Table A-5. Service Setup 2 CDU Configuration Settings (continued)
TAKEOVER METHOD:
NONE (default)
Sets the control acquisition method for the
TAKEOVER METHOD CALL UP
station. Refer to chapter 2.
TAKEOVER
AUDIBLE TAKEOVER:
YES (default) Determines if a beep is sounded when the

AUD TAKEOVER
NO station takes control.
AUDIBLE BUTTON:
YES (default) Determines if beep is sounded when a

AUD BUTTON
NO button is pressed.
SERVICE INTERFACE:
2400
4800 (default) Sets the Baud Rate for the diagnostic serial
BAUD RATE
9600 port.
19200
NO PARITY (default)
Sets the Parity Bits for the diagnostic serial
PARITY BITS EVEN
port.
ODD
7 Sets the Data Width for the diagnostic serial
DATA BITS
8 (default) port (future enhancement).
1 (default) Sets the number of Stop Bits for the

STOP BITS
2 diagnostic serial port (future enhancement).
CAN INTERFACE:
Sets the Baud Rate on the NAVINET 4000

BAUD RATE 250K (default)
Steering Control Network bus for the unit.
A-28 JA19-8039F
Table A-6. Service Setup 2 SYS Configuration Settings
Enables or disables the NAVIPILOT 4000s Adaptive Self-Tuning

feature (see Chapter 2, section 2.18):
PID (default)
PID (Proportional Integral Derivative) - Adaptive Self-Tuning is
AD disabled.
SYSTEM
PID/MST AD (Adaptive) - Adaptive Self-Tuning is enabled.
AD/MST PID/MST (Main Steering) Same as PID.
AD/MST Same as AD.
A.4 SYSTEM CONFIGURATION

A number of important system characteristics are not configured via the service setup menus. Use Figure A-2 to
record this information. The row of data entered becomes the Configuration ID Number, which is a useful record
to assist with analysis if a problem is reported. It is recommended that the vessel keep a copy of the Configuration
ID Number, and for the installing engineer to record the number to be kept with records of the installation.
JA19-8039F A-29
NAVIPILOT 4000
Date: Ship Name: Installer:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1 Total No. of SCUs

2 No. of Port SCUs
3 No. of Stbd SCUs
4 No. of DC Solenoid Interface Cards
5 No. of AC Solenoid Interface Cards
6 No. of Isolated Proportional Output

Interface Cards
7 Master/Slave Configuration (see Note 1)
8 Independent DRS? (Y = yes; N = no)
9 Mode Switch Type (0 = none;
1 = Mechanical Mode Switch [MMS];
2 = Steering Mode Selector [SMS])
10 Mode Switch Choices Standby (NFU)
(S = Mode Available; X = Mode Not Available)
11 Mode Switch Choices Helm (Hand/FU)
(H = Mode Available; X = Mode Not Available)
12 Mode Switch Choices Auto
(A = Mode Available; X = Mode Not Available)
13 Mode Switch Choices Remote
(R = Mode Available; X = Mode Not Available)
14 Mode Switch Choices External
(E = Mode Available; X = Mode Not Available)
15 Analog Helm? (Y = yes; N = no)
16 No. of Follow-Up Mini-Wheels (FMW) at Main
17 No. of CDUs at Main
18 Modes Available at CDU (see Note 2)
19 Total No. of Remote Locations
20 No. of Remote Locations With CDU
21 External Override? (Y = yes; N = no)
22 ABS Override? (Y = yes; N = no)
23 External System? (Y = yes; N = no)
24 Software Revision Letter

NOTES:
1. For Master/Slave Configuration, enter one of the following codes:
N1 - Only one SCU is powered on and on its own CAN bus, with no other SCU's connected
Y2 - Two SCUs on the same CAN bus are normally powered on at the same time, with master/slave relationship
Y3 - Three SCUs on the same CAN bus are normally powered on at the same time, with master/slave relationship
Y4 - Four SCUs on the same CAN bus are normally powered on at the same time, with master/slave relationship
2. For Modes Available at CDU, enter one of the following codes:

A AUTO, NAV, and TRACK
U AUTO only
N AUTO and NAV
T AUTO and TRACK
NAV mode requires connection to Sperry VMS/ECDIS. TRACK mode requires connection to a compatible chart system or GPS.
Figure A-2. Configuration ID Number
A-30 JA19-8039F
Appendix B
APPENDIX B
SERVICE SETUP CONSIDERATIONS
FOR NAVIPILOT 4000 TUNING
B.1 INTRODUCTION.
The NAVIPILOT 4000 must be properly tuned in order to steer the ship effectively and efficiently. Tuning
procedures for the NAVIPILOT 4000 are described in section 2.18 of this manual. However, before the
NAVIPILOT 4000 can be successfully tuned, the Service Setup parameters for the specific application must be
configured correctly, as described in Appendix A. The following setup parameters are particularly critical to
successful NAVIPILOT 4000 tuning:
Ships Time Constant (Tau). The time (in seconds) that it takes the vessel to sail its own length
(length at waterline) at its service speed.
Rudder Gain (RG). The sensitivity of the NAVIPILOT 4000s response to heading errors. RG is
also referred to as Proportional Gain, because it generates rudder orders proportional to the
heading error. Increasing the RG value increases the sensitivity.
Counter Rudder (CR). The sensitivity of the NAVIPILOT 4000s response to turn rate. CR is
also referred to as Rate Gain, because it generates rudder order in direct response to the turn
rate of the ship. Increasing the CR value increases the amount of counter rudder, and hence
reduces the tendency for the ship to overshoot the desired heading.
The tuning process does not affect the Tau value. Therefore, before tuning is performed, it is critical that the
Tau value be set accurately, based on vessel length at the waterline and service speed. Filtering and timing
within the NAVIPILOT 4000 is speed-scaled from the Tau value. If the Tau value is not accurate, it will be difficult
or impossible to achieve good performance.
RG and CR are adjusted during the tuning process to their proper values. However:
The tuning process is facilitated by initial RG and CR settings which are appropriate for the
vessel. Initial overshoot/undershoot is reduced, the time required for tuning is reduced, and the
quality of the tuning level achieved may be significantly improved.
If Tuning is reset, RG and CR will be reset to the initial values entered in the Service Setup
menus. If the initial RG and CR values are not appropriate, the NAVIPILOT 4000 may be unable
to steer the ship effectively.
This Appendix contains the instructions for calculating Tau, and for selecting the appropriate default values for RG
and CR.
B.2 CALCULATING TAU.
The value of Tau is entered using the SERVICE SETUP 1 menu, as described in Appendix A. Calculate the
value of Tau as follows:

Tau (seconds) = x 1.94
or:
Ship Length (feet)

Tau (seconds) = x 0.592
Length is ship length between perpendiculars (Lpp), or design waterline length. Service speed is the typical
operating speed of the vessel. Calculated Tau will range from low values (4 or less) for small vessels with high
service speeds, to high values (36 or more) for large super-tankers with relatively low service speeds.
JA19-8039F B-1
NAVIPILOT 4000
Figure B-1 is a nomogram illustrating the Tau formula. In the example shown in Figure B-1:
Vessel length between perpendiculars = 225 meters

Vessel service speed = 18 knots
225
18 x 1.94 = 24.25 24 seconds
Tau (seconds) =
Tau (seconds) = 40 35 30 25
20
300
Tau=24
250
15
200
10
150
100
5
50
2
0
5 10 15 20 25 30
Figure B-1. Tau Formula Nomogram
Also note that the appropriate value of Tau must be input for each of the NAVIPILOT 4000s operator-selectable
loading conditions. For Adaptive Self-Tuning operation, two separate tunings are maintained: Light (for use when
the ship is lightly loaded), and Loaded (for use when the ship is heavily loaded). For Manual Tuning operation,
three separate tunings are maintained: Light, Medium, and Loaded. For each loading condition, a different Tau
value may be entered in the SERVICE SETUP Menu. Normally, Tau should be set to the same value for all
load conditions. The exception is the case of Notch Tugs, where two Tau settings can be used for the two
operating conditions of the vessel: (1) When the Notch Tug is operating as an unattached tugboat (in which case
the ship length is short, producing a small Tau), and (2) When the Notch Tug is docked into a ship-shaped hull
(producing a much longer ship length, and thus a large Tau).
B-2 JA19-8039F
Appendix B
B.3 SELECTING THE INITIAL RUDDER GAIN (RG) AND COUNTER RUDDER (CR) VALUES
The initial values of Rudder Gain (RG) and Counter Rudder (CR) are entered using the SERVICE SETUP 1
Menu, as described in Appendix A. These values are retained in memory, and are the initial RG and CR values
for the Adaptive Self-Tuning procedure when the user selects RESET TUNING. The current RG and CR may
differ from the initial values, due to adjustments made during Adaptive Self-Tuning, or due to adjustments made
manually. Note: the initial RG and CR values have no consequence when Adaptive Self-Tuning is NOT enabled.
Before performing an initial tuning sequence, the initial RG and CR values should be set as follows:
RG - Normal configurations 1.4
RG - High-lift rudder configurations 0.7
CR 1.0
Normally, the initial values will require no further changes. The user may select manual tuning if it becomes
necessary to modify the RG and/or CR values in use. This will not change the stored initial values for RG and CR.
The RG and CR settings shown above work well for most vessels. However, there may be special cases for
which these initial values do not result in acceptable tuning. In such a case, manually tune to determine the best
final tune settings for the vessel and for the vessels loading condition. If the manual tuning indicates that the
appropriate RG and CR values are significantly different from the default values shown above, request that Sperry
Field Service update the initial values of RG and CR in the Service Setup menus accordingly. Thereafter, allow
Adaptive Self-Tuning to continue to adjust to loading changes over time and usage.
JA19-8039F B-3
NAVIPILOT 4000
THIS PAGE LEFT BLANK
B-4 JA19-8039F
Appendix C Acronyms and Abbreviations
APPENDIX C
ACRONYMS AND ABBREVIATIONS
ABS American Bureau of Shipping FMW Follow-Up Mini-Wheel/Display Unit

AC Alternating Current
ACT HDG Actual Heading G/M Gyro/Magnetic
AD Adaptive GPS Global Positioning System
ADG Adaptive Digital Gyropilot
A/N/T Auto/Nav/Track HCS Heading Control System
A/N/T/E Auto/Nav/Track/External HDG Heading
AUTO Automatic HDG DIFF Heading Difference
Aux Auxiliary HSC Heading to Steer Command
HTC Heading To Complete
BEAR Bearing HTD Heading Track Control Data
BIAS Rudder Order Bias
BIU Bus Interface Unit IMO International Maritime Organization
BPS Bits Per Second INF Seaway Influence
INIT Initialization
CAGE Commercial and Government Entity IO Input Output
CAL Calibration
CAN Controller Area Network Kn Knot
CDU Control and Display Unit Kbps Kilobits Per Second
CHG Change
CIU CAN Interface Unit L Log
COMP MAN Complete Maneuver LCD Liquid Crystal Display
CR Counter Rudder LIM Limit
CRS Course LVL Tune Level
DC Direct Current MAG Magnetic

DEG Degree MAG VAR Magnetic Variation
DISP OPT Display Option MIN Minute
DNV Det Norske Veritas MMS Mechanical Mode Switch
DPS Dynamic Positioning System MOSFET Metal Oxide Semiconductor Field-
DRS Dual Rudder Sync Selector Effect Transistor
MSG Message
E East MSU Manual Steering Unit
ECDIS Electronic Chart Display and
Information System NAD Network Address
EMF Electromotive Force NAV Navigation
En Enable NC Normally Closed
Err Error NFU Non Follow-Up
Ext External NM Nautical Mile
NMEA National Marine Electronics
FID Follow-Up Interface/Display Unit Association
FU Follow-Up NO Normally Open
JA19-8039F C-1
NAVIPILOT 4000
Ord Order SMS Steering Mode Selector

SMN/NFU Steering Mode Selector/ Non-
PCB Printed Circuit Board Followup Tiller
PID Proportional Integral Derivative SOG Speed Over Ground
PRE Proportional to Rudder Error SPD Speed
PRO Proportional to Rudder Order SPST Single-Pole, Single-Throw
PROM Programmable Read Only Memory SRC Source
PROP Proportional Stat Status
PROP-HTC Proprietary Heading-To-Complete SPS Steering Position Selector
Stbd Starboard
RAD ORD Radius Order STW Speed Through Water
RAM Random Access Memory SYNC Synchronize
RG Rudder Gain
RRB Rudder Repeatback TRK Track
RSA Rudder Sensor Angle
RUD Rudder VAC Volts Alternating Current
RUD ANG Rudder Angle VDC Volts Direct Current
RUD LIM Rudder Limit VDR Voyage Data Recorder
RUD ORD Rudder Order VMS Voyage Management System
SAM Steering Alarm Module W West

SCR Silicon-Controlled Rectifier WCU Wheel Control Unit
SCU Steering Control Unit
SEC Second XT Cross Track
XTE Cross Track Error
C-2 JA19-8039F

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JA19-8039

Also applicable to the ADG 4000 Autopilot

Copyright 2006 Northrop Grumman Systems Corporation (Sperry Marine)

Northrop Grumman Systems Corporation 15 June 2006

Also applicable to the ADG 4000 Autopilot

Copyright 2006 Northrop Grumman Systems Corporation (Sperry Marine)

Northrop Grumman Systems Corporation 15 June 2006

TABLE OF CONTENTS - Continued

2.18.2.1 TUNING Display ..................................................................................................... 2-32

3 INSTALLATION AND INITIALIZATION

B SERVICE SETUP CONSIDERATIONS FOR NAVIPILOT 4000 TUNING

C ACRONYMS AND ABBREVIATIONS ..................................................................................... C-1

1-1 NAVIPILOT 4000 and Ancillary Equipment ............................................................................ 1-0

2-1 NAVIPILOT 4000 CDU Display ............................................................................................... 2-1

3-1 Steering Control Unit PCB ...................................................................................................... 3-2

A-1 Typical MAIN SERVICE SETUP Menu ................................................................................... A-5

B-1 Tau Formula Nomogram ......................................................................................................... B-2

1-1 Dimensions and Weights ........................................................................................................ 1-3

2-1 NAVIPILOT 4000 CDU Display ............................................................................................... 2-2

3-1 SCU Jumper Configurations ................................................................................................... 3-1

4-1 Fault Codes ............................................................................................................................. 4-3

ALWAYS keep technical manuals in a well-known, readily available location.

NEVER exceed specified system power OR environmental limits.

NEVER install unauthorized additional cards OR devices into this system.

NEVER provide unauthorized modifications to this system.

Figure 1-1. NAVIPILOT 4000 and Ancillary Equipment

The standard features of the NAVIPILOT 4000 include:

The Adaptive Self-Tuning feature adds:

1.3 EQUIPMENT DESCRIPTION

Northrop Grumman Sperry Marine GmbH and Co. KG

1.3.1 Control and Display Unit (CDU)

1.3.2 Steering Control Unit (SCU)

1.3.3 NAVINET 4000 Steering Control Network

Table 1-1. Dimensions and Weights

Control and Display Unit (CDU)

Depth 44 mm (requires 150 mm minimum clearance for interface cable)

Steering Control Unit (SCU)

Height 400 mm (requires 550 mm minimum for interface cable clearance)

Depth 152 mm (requires 280 minimum clearance for cover removal)

Table 1-2. NAVIPILOT 4000 Equipment Part Numbers

Part Number Description Notes

NAVIPILOT 4000 Control and

ADG 4000 Control and Display Unit Superseded by part number

4000 Series Steering Control Unit

20456 Cable For replacement purposes.

Table 1-3. Optional Equipment Used With the NAVIPILOT 4000

20040 AC Solenoid Daughter Interface to steering gear. 24-230VAC, 4 ampere in rush, 1

20041 AC Solenoid Daughter Interface to steering gear. 24-230VAC, 4 ampere in rush, 1

20042 DC Solenoid Daughter Interface to steering gear. 12-110VAC, 2 amperes maximum.

20043 DC Solenoid Daughter Interface to steering gear. 12-110VAC, 2 amperes maximum.

Current loop: Loop impedance 20 to 150 ohms.

Current loop (4-20mA) must be configured before use.

Pump on sense: contact closure < 1 ohm ON, 100K OFF.

Figure 1-2. Control and Display Unit (CDU)

Figure 1-3. Steering Control Unit (SCU)