TILLERPILOT

TP22 & TP32

SERVICE MANUAL

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Simrad Margate Ltd

Star Lane, Margate, Kent CT9 4NP,UK

Telephone +44 (0) 1843 290290
Facsimile +44 (0) 1843 290471

CONTENTS
1 INTRODUCTION

2 OPERATION

3 DISASSEMBLY / ASSEMBLY INSTRUCTIONS

4 MECHANICAL ASSEMBLY DRAWINGS

5 CIRCUIT DESCRIPTIONS

6 CIRCUIT DIAGRAMS

6.1 Circuit Schematics

6.2 Component Lists and Layouts

7 PROGRAMMING AND CONFIGURATION

8 FAULT FINDING

8.1 Common User Faults

8.2 Common Technical Faults

9 SPARE PARTS DETAIL

9.1 Spares
9.2 Service Aids
9.3 Accessories

10 TECHNICAL NOTES

© 2004 Simrad Margate Ltd

The technical data, information and illustrations contained in this publication were to the best of our knowledge correct at the time of going to print.
We reserve the right to change specifications, equipment, installation and maintenance instructions without notice as part of our policy of continuous
development and improvement. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic or
otherwise without prior permission from Simrad Margate Ltd. No liability can be accepted for any inaccuracies or omissions in the publication, although
every care has been taken to make it as complete and accurate as possible.

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Section 1

Introduction
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1 INTRODUCTION TO THE TP22 AND TP32 TILLERPILOTS

The TP22 and TP32 Tillerpilots combine highly sophisticated electronics with advanced software
and powerful mechanical drive to provide accurate and reliable steering performance under a
variety of different conditions with minimal current consumption.

TP22 – is suitable for tiller-steered sailing yachts up to 10m (34 ft) in length and offers a range of
sophisticated functions, including additional remote control facilities, Steer to Wind and Nav (Steer
to GPS) modes using external equipment linked directly to the Tillerpilot via the SimNet high-speed
bus or through the inbuilt NMEA0183 interface.

TP32 – offers the same facilities as the TP22 with an improved re-circulating ball screw drive and
is suitable for tiller-steered sailing yachts up to 12.8m (42 ft) in length.

SimNet is an intelligent network system provided to facilitate integration of Simrad products by

sharing data. The system is built around CanBus, a true multi-talker bus system with high levels of
error protection and all units are interconnected using a standard single cable.

The Pilot can receive navigational information from a Chartplotter for Steer To GPS (Nav mode),
and will also accept wind angle data, from the wind transducer for Steer To Wind mode, boat
speed data from the speed instrument and heading data from the compass transducer.
Additionally, heading data from the Pilot can be displayed on any instrument display capable of
showing compass information.

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Tillerpilots TP22 & TP32

Section 2

Operation
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2 OPERATING INSTRUCTIONS

This Service Manual only contains operating instructions for those features of the Simrad Tillerpilot
range that are not normally available to the end user. For details of normal operation please refer
to the appropriate Simrad Instruction Manual.

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 Tillerpilots TP22 & TP32

Section 3

Disassembly / Assembly Instructions

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3 DISASSEMBLY / ASSEMBLY INSTRUCTIONS

Tillerpilot : TP22. Refer to Drawing Number E04587.

Disassembly

Remove and retain the 10 case screws 200005 and separate the case halves. Remove the Screw
(200139) securing the “Wits” Fixing (200196) and lift the Grommets (190036) retaining the cable
loom from their supports to facilitate separation. Fold down the Pivot Pin (E02501) from the recess
in the case and lift clear. Remove and discard the Main Case Seal (E02498); seals frequently
become distorted and good engineering practice dictates their replacement.

Main PCB. Remove and retain the 6 Screws (200139) securing the Main PCB Cover (E02680:BK)
to gain access to the PCB. Remove and discard the Internal Seal (E02499). Remove the Compass
Assembly (E02637) by unplugging the connector from the PCB and disengaging the compass
housing from the lugs in the PCB Cover. De-solder and remove the cable connections and
withdraw the cables through the 2 Grommets (E04534 and E04536).

Feedback PCB. Remove and retain the 2 Screws (200139) and release the Feedback PCB
(E03184). De-solder and remove the cable connections.

Motor and Drive Assembly

Unscrew and retain the Tiller Connector (E00111) from the end of the Push Rod (E02522).
Remove and retain the 2 Screws (200137) securing the Bearing Clamp (E02497:BK) and lift away.
Release the top Screw (200082) from the Front Motor Mount (E02502) and remove and retain the
Anti Static Strap (E04493). Lift the Motor Assembly (E02788) from its retaining slots, whilst
simultaneously disengaging the Drive Belt (280027) from the motor drive pulley. De-solder and
withdraw the motor supply cables. Lift the 71-Tooth Pulley (E02505) located on the end of the
Drive Assembly (E03264), disengage and remove the Drive Belt and withdraw the Drive Assembly.
Remove the 2 End Cap (E02495:BK) retaining Screws (200055) and withdraw the End Cap and
seals. The Tillerpilot Cable Assembly (E04584) may be withdrawn through the Grommet (E04533)
once the cable ties and fixings have been released.

Assembly

Assembly is the reverse of disassembly but the following points should be noted:

Motor and Drive Assembly. Before fitting the Drive Assembly the “trough” area and the bore
which houses the seal, “O” ring and spacer should be lightly greased. The Push Rod Seal
(E00747) has a tapered inner bore and should be fitted into the case with the larger bore of the
seal facing outwards. Fit “O” Ring 190026, spacer E02870 and End Cap E02495, ensuring that the
end cap is pushed fully home before the retaining screws are tightened. After assembly, refer to
the sketch below and check that the drive belt tension is within +/- 3mm.

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Main PCB. Refer to drawing E04587 and, ensuring that the wires from the compass to the
connector lie over the PCB, insert plug into the socket on the PCB. Clip the compass Assembly
into the PCB Cover (it can only be fitted one way around), ensuring that the lugs on the compass
assembly line up with the 2 holes in the PCB cover.

Final Assembly. Carefully position the case top onto the bottom ensuring that the case seal and
Dowel Pin (200322) locate correctly, squeeze the top and bottom halves of the case together and
fit the 10 screws (200088). Tighten down evenly all round in the sequence shown below:

Post Assembly Test. Remove the Tiller Connector E00111 and push the Tillerpilot Test Syringe
Part No. TP-SRY over the end of the Push Rod E02522. Depress the syringe piston and release,
the piston should return to its original position indicating that the integrity of the case seal has not
been compromised during fitting. Remove the Test Syringe and refit the Tiller Connector.

Tillerpilot : TP32. Refer to Drawing Number E04581.

Disassembly and assembly are identical to the TP22 with the following exception:

Drive Assembly E02618. The Drive Assembly employs a re-circulating ball screw and the
assembly is held in place by the metal mounting plate sitting in the mounting slots in both top and
bottom cases.

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Section 4
Mechanical Assembly Drawings

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4 MECHANICAL ASSEMBLY DRAWINGS

General Assembly : TP22 E04587

General Assembly : TP32 E04581

Assembly : Tillerpilot Flanged Outlet E04530

Cable Assembly : Power E04584

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Section 5
Circuit Descriptions
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5 CIRCUIT DESCRIPTIONS

Common PCB Assembly

Introduction. The PCB Assembly is a common item to all Wheelpilots and Tillerpilots. Refer to
Drawing No. E04506.

Supply and Regulation. The Tillerpilots are designed to work from a 12V source. Protection
against incorrect polarity is provided by D1 and D4. Capacitors C1and C3 are used as reservoirs
to hold up the supply voltage and reduce any supply dips. Protection against over-voltage spikes is
provided by Resistor R2 and Zener Diode ZD1 and Regulator REG1 provides a 5V regulated
supply. Transient Voltage Suppresser TVS1 protects the MOSFET drive transistors, TR10 to
TR13, from voltage spikes greater than +16V.

Microprocessor Port Allocations. The microprocessor IC2 port allocations are given in the table
below. The ‘Port Reference’ column is split into two for all I/O pins, the left section is the general
purpose I/O reference and the right section is the alternate function. The alternate function is
highlighted when used. All pins not given a ‘Signal Name/Description’ should be left unconnected.

Port Pin Signal Signal

Reference Number Name Description
P0.0 ST0.0 54 TP1
P0.1 ST0.1 53 TP2
P0.2 ST0.2 52 TP3
P0.3 ST0.3 51 TP4 Test Points
P0.4 ST0.4 50 TP5
P0.5 ST0.5 49 TP6
P0.6 ST0.6 48 TP7
P0.7 ST0.7 47 TP8
P1.0 ST1.0 46 MUXSELA MUX Select A (IC9/10)
P1.1 ST1.1 45 MUXSELB MUX Select B (IC9/9)
P1.2 ST1.2 44 MUXINH MUX Inhibit (IC9/6)
P1.3 ST1.3 43 PULLCAL Pulled Cal Drive (R49)
P1.4 ST1.4 42
P1.5 ST1.5 41
P1.6 ST1.6 40 COILB Drive for FLUXGATE, phase B (R41)
P1.7 ST1.7 39 COILA Drive for FLUXGATE, phase A (R40)
P2.0 ST2.0 62 TP1
P2.1 ST2.1 61 TP2
P2.2 ST2.2 60 TP3
P2.3 ST2.3 59 TP4 Test Points
P2.4 ST2.4 58 TP5
P2.5 ST2.5 57 TP6
P2.6 ST2.6 56 TP7
P2.7 ST2.7 55 TP8
P3.0 ST3.0 38 NAVLED Drive for NAV LED (TR5)
P3.1 ST3.1 37 HRSYNC Sync for HR200 controller (R18/R19)
P3.2 ST3.2 36 AUTOLED Drive for STBY/AUTO LED (TR4)
P3.3 ST3.3 35 STBDLED Drive for STBD LED (TR3)
P3.4 ST3.4 34 PORTLED Drive for PORT LED (TR2)
P3.5 ST3.5 33 BEEP Drive for BUZZER (R59/R60)
P3.6 ST3.6 32
P3.7 ST3.7 31
P4.0 30
P4.1 CTX 29 CANTX CAN TX Output (IC1/4)
P4.2 CRX 28 CANRX CAN RX Output (IC1/1)
P4.3 27
P4.4 26

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P4.5 25
P4.6 24
P4.7 23
P5.0 KW0 22 TACKKEY TACK Key (S4)
P5.1 KW1 21 PORTKEY PORT Key (S1)
P5.2 KW2 20 STBDKEY STBD Key (S2)
P5.3 KW3 19 AUTOKEY STBY/AUTO Key (S3)
P5.4 KW4 18 NAVKEY NAV Key (S5)
P5.5 KW5 17
P5.6 KW6 16
P5.7 KW7 15
P6.0 10
P6.1 9
P6.2 INT0 6 FB1 Hall Effect Feedback (PIN 2)
P6.3 INT1 5 FB2 Hall Effect Feedback (PIN 3)
P6.4 TX0 4
P6.5 CNTR0 3 FLUXCOS FLUXGATE COS Input (IC7/1)
P6.6 CNTR1 2 FLUXSIN FLUXGATE SIN Input (IC7/7)
P6.7 PWM 1
P7.0 AN0 80 DRIVEA Drive for MOTOR, phase A (R62)
P7.1 AN1 79 DRIVEB Drive for MOTOR, phase B (R71)
P7.2 AN2 78
P7.3 AN3 77
P7.4 AN4 76 LK0 Debug Mode Select (New link)
P7.5 AN5 75 LK1 Model Select 1 (LK1)
P7.6 AN6 74 LK2 Model Select 2 (LK2)
P7.7 AN7 72 LK3 Model Select 3 (LK3)
P8.0 SIN1/RXD1 70 NMEA NMEA Input (TP15)
P8.1 SOUT1/RXD1 69
P8.2 SCLK1/CTS1 68 0V Connected to 0V Rail
P8.3 SRDY1/RTS1 67
P8.4 SIN2/RXD2 66 NVMDO NVM Data Output DO (IC3/4)
P8.5 SOUT2/RXD2 65 NVMDI NVM Data Input DI (IC3/3)
P8.6 SCLK2/CTS2 64 NVMSK NVM Serial Clock SK (IC3/2)
P8.7 SRDY2/RTS2 63 NVMCS NVM Chip Select CS (IC3/1)
RESET 8 RESET Reset Input (R15)
VSS 11 0V Connected to 0V Rail
XIN 12 XTAL Crystal (XTAL1)
XOUT 13 XTAL Crystal (XTAL1)
VCC 14 5V Connected to 5V Rail
AVSS 71 0V Connected to 0V Rail
VREF 73 No Connection
CNVSS 7 0V Connected to 0V Rail

Microprocessor Reset. Integrated Circuit IC6 is an integrated reset generator for the
microprocessor which produces a reset LOW pulse of approximately 50mS duration at switch on
and whenever a 5v supply failure occurs. In addition to the reset provided by IC6, the
microprocessor has a built-in watchdog timer, which will create a reset if a software crash occurs
for any reason.

Non-Volatile Memory (NVM). Integrated Circuit IC3 provides 1Kbit of E2 memory for the retention
of important data after power down.

Keypad. Light Emitting Diodes LED1 to LED4 are driven from Ports P3.3 to P3.0 and turn OFF
when the line goes HIGH via the transistor switches TR2 to TR5. When the transistors are off,
resistors R32, R34, R36 and R38 provide a low current path for the LEDs to provide low-level night
illumination. The Audio Resonator AR1 is self-resonating and switches ON when Port P3.4 goes
HIGH via the transistor switch TR1 and resistors R59 and R60. The control key lines on Ports P5.0

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to P5.4, normally pulled to +5V via resistors R7 to R11, are “scanned” by the microprocessor to
detect if any of the switches have been operated and pulled the line LOW.

NMEA Data In. NMEA data is optically isolated by IC5 and then fed into Port P8.0 of the
microprocessor.

SimNet Interface. SimNet is an intelligent network system provided to facilitate integration of

Simrad products. The system is built around CanBus, a true multi-talker bus system with high
levels of error protection. The bus protocol is encoded and decoded by a dedicated circuit built into
the micro-controller. The CanBus driver IC1 provides the physical layer interface to the
interconnection between Simrad products.

The micro-controller is completely isolated from the CanBus by high-speed opto-couplers IC4 and
IC12. The CanBus side of these devices and the driver IC1 are powered from the CanBus supply
provided by REG2 and associated components.

Configuration Links. The Links, L1, L2 and L3, are used to configure the Microprocessor to either
Wheelpilot or Tillerpilot operation and to model versions 10, 22 or 32 in accordance with the table
below:

1 Model Link 1 Link 2 Link 3

TP 10 N/C N/C N/C
WP 10 N/O N /C N/C
TP 22 N/C N/O N/C
TP 32 N/C N/O N/O
WP 32 N/O N/O N/O

LEGEND N / C Normally Closed (soldered)

N/O Normally Open (unsoldered)

Fluxgate (Compass). Two anti-phase signals are provided from microprocessor Ports P0.6 and
P0.7. These signals are buffered by TR15 and TR16 to provide a higher current drive to the
excitation coil of the fluxgate. A reference voltage level of +2 volts is provided by R46 and R53
decoupled by C53. The 2 coils, mounted at right angles, provide output signals proportional to the
sine and cosine of the Earth’s magnetic field. These signals are fed via the electronic switch IC9 to
2 dual-slope integrating analogue-to-digital converters IC7 and IC 8, plus associated components.
The outputs of the comparator IC7 are fed to the microprocessor Ports P6.5 and P6.6, which
provide input-capture facilities. Accurate timing of the conversion is kept by the microprocessor to
provide simultaneous precision analogue to digital conversion of both sine and cosine signals to
avoid errors created by multiplexing the inputs.

Motor Drive. The motor drive signals (MDRIVE_A and MDRIVE_B) are generated from the
microprocessor at Ports P7.0 and P7.1, these lines being LOW when there is no drive and HIGH to
drive. The drive outputs control IC10 and IC11, which are comparators set at threshold levels of
+4V and +1V produced by the resistor network R71, R72 and R73. The comparators invert the
signals and provide the current to switch the MOSFETs in stages, which prevents both P and N
channel MOSFETs on the same side of the “H-bridge” configuration (i.e. TR10 and TR11, or TR12
and TR13), being partially switched on at the same time. When there is no drive, both N-channel
MOSFETs TR11 and TR13 are switched on giving a direct short across the motor to the 0V line,
thus providing active braking.

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EMC. Capacitors with values of 100pF, 100nF and 1nF are extensively used to decouple noise
from switched data lines. Two A.C. coupled connections labelled “CHASSIS”, routed via capacitors
C63 and C64, where provided for interconnection to the internal metalwork for EMC purposes.
Tests have confirmed that connection is not required.

Hall Effect PCB.

Introduction. The Hall Effect PCB is a generic item, which can be used for both Tillerpilots TP10,
TP22 and TP32 and Wheelpilots WP10 and WP32. For Tillerpilots, the Hall Effect devices are
mounted vertically into the PCB and horizontally for Wheelpilots. The circuit diagram for the Hall
Effect PCB is given in Drawing No. E03182.

Feedback. Two Hall Effect sensors HE1 and HE2 are mounted on the Hall Effect PCB and sense
the rotation of 2 small bar magnets mounted 1800 apart in the pulley wheel. This produces a
quadrature feedback output, at logic levels, FB1 and FB2. The PCB is powered from the host unit
+5V regulated supply, the line being filtered by C1, and signals FB1 and FB2 are fed back to the
microprocessor Ports P6.2 and P6.3 via pull-up resistors on the host unit PCB.

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Section 6
Circuit Diagrams
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6 CIRCUIT DIAGRAMS

Circuit Schematics

Common PCB Circuit Diagram E04506

Hall Effect PCB Circuit Diagram E03182

Component Lists and Layouts

Common PCB Assembly Detail E04508

Hall Effect PCB Assembly Detail E03184

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Section 7
Programming and Configuration
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7 PROGRAMMING AND CONFIGURATION

This Service Manual only contains programming and configuration information for
those features of the autopilot, which are not normally available to the end user. For
details of normal programming and configuration please refer to the appropriate user
manual.

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Tillerpilots TP22 & TP32

Section 8
Fault Finding
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8 FAULT FINDING

Common User Faults. Common user faults are included in the Diagnostics
Guide in the user manual.

Common Technical Faults. None yet identified.

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Section 9
Spare Parts Detail
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9 SPARE PARTS DETAIL

Spares Packs

TPPK6 FLUXGATE ASSEMBLY

TPPK8 MOTOR ASSEMBLY
TPPK10 DRIVE BELT
TPPK22 TP32 MECHANICAL ASSEMBLY
TPPK26 FEEDBACK KIT
TPPK321 TP22/TP32 PACKING KIT
TPPK322 TP22 MECHANICAL ASSEMBLY
TPPK323 TP22 TOP CASE
TPPK324 TP22/TP32 BOTTOM CASE
TPPK325 TP22/TP32 MAIN PCB COVER
TPPK326 TP22/TP32 CASE SCREW PACK
TPPK327 TP22/TP32 PUSH ROD SEAL KIT
TPPK328 TP22/TP32 MAIN CASE SEAL
TPPK329 TP22/TP32 MAIN CASE SEAL

E04586 TP22/TP32 USER MANUAL

9.2 Accessories

TB30 TILLER BRACKET 30mm

TB60 TILLER BRACKET 60mm
TB90 TILLER BRACKET 90mm
TB120 TILLER BRACKET 120mm
PB30 PEDESTAL BRACKET 30mm
PB60 PEDESTAL BRACKET 60mm
PB90 PEDESTAL BRACKET 90mm
CB1 CANTILEVER BRACKET
PRE30 PUSH ROD EXTENSION 30mm
PRE60 PUSH ROD EXTENSION 60mm
PRE90 PUSH ROD EXTENSION 90mm
PRE120 PUSH ROD EXTENSION 120mm
PRE150 PUSH ROD EXTENSION 150mm
PRE300 PUSH ROD EXTENSION 300mm
SKT22/32 WATERPROOF BULKHEAD SOCKET & CABLE ASSEMBLY

9.3 Service Aids

TP-SRY TILLERPILOT TEST SYRINGE

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Section 10
Technical Notes
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10 TECHNICAL NOTES

Technical Bulletin PS184 Dated 26/04/2004 SimNet Data Source Selection

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TECHNICAL BULLETIN

NO. PS184 DATE: 26/04/2004

SimNet Data Source Selection

IS12 & SimNet Enabled Cockpit Pilots

Background powerup continuing to press and hold until the

display appears.
One of the features of SimNet is that the user can select
specific data sources when multiple sources are present. The instrument will lock onto the correct local data
For example a system with an IS12 Compass and AP25 source and any secondary sources can now be
will have two sources of SimNet Compass information. connected.
SimNet IS12 is capable of selecting either source. This
facility is available on IS12 Wind, Data, Mega and Cockpit Pilots, TP22, TP32 and WP32
Compass and on the new Cockpit Pilots.
To reset and select the correct local SimNet data source is
The first time that any one of these products is connected also a simple matter.
to a data source it locks on such that the data source
becomes assigned to the product. If at a later date the user With the power off ensure that only the specific data
wants to use the product with a different data source then source required is connected to the network.
the product needs to be reset. If an Instrument does not
recognise the attached data source it will display three Press and hold the Tack and Starboard keys and then
bars and will need to be reset. If a Cockpit pilot does not powerup continuing to press and hold until all LED's
recognise the attached data source it will behave as if light up.
there is no data source present.
The instrument will lock onto the correct local data
The Depth, Speed and Combi IS12 do not have this source and any secondary sources can now be
facility and will only ever read data from the transducer connected.
that they are directly connected to.
Procedure following servicing
Procedure
Prior to returning serviced units to customers they will
IS12 need to be cleared down to ensure that the unit locks onto
the customer's local data source on first power up without
To reset and select a specific local SimNet data source is the need for the customer to go through the reset
a simple matter procedure.

With the power off ensure that only the specific data The Instruments and Pilots are cleared down by
source required is connected to the network. following the relevant steps above but without any
SimNet data connected, just power.
Press and hold the right hand key of the instrument
(Wind, Data, Mega or Compass as required) then

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Contact Information
If you have any further queries, please contact :
Duncan Riddle
Manager, Customer Support
[email protected]
Simrad Margate
Star Lane, Margate, Kent
CT9 4NP, United Kingdom
Tel +44 (0) 1843 290290Fax +44 (0) 1843 290471

Yyyy/mm/dd/Initials

Please circulate to:

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