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Lewmar Integra Autopilot Drive - User Manual

Lewmar Integra Autopilot Drive
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Autopilot Drive
Product manual
Owner’s Installation, Operation & Servicing manual
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Summary

1- Introduction

Product Support

Information on obtaining technical assistance and locating distributors worldwide.

CE Approvals

Details on how to obtain CE approval certificates for Lewmar products.

Important Information About This Manual

Guidance on understanding safety and product damage warnings within the manual.

2- Safety Notice

General Safety Warnings

Critical precautions for safe operation, hazard avoidance, and manual control readiness.

EMC Recommended Guidelines

Guidelines for ensuring optimal Electromagnetic Compatibility performance during installation.

3- Installation

3.1 Overview of Drive Kits

Introduction to different autopilot drive kits: Bavaria, Mamba, and Cobra.

3.2 Preparation and Mounting

Guidance on preparation, general position, environment, and structural strength for installation.

3.3 Optional Rudder Reference Unit Setup

Procedure for setting the optional rudder reference unit potentiometer to its midpoint.

3.4 Constellation Chain and Sprockets

Details on chain size, sprocket selection, and installation for Constellation drives.

Sprocket for Steering Shaft

Instructions for selecting and fitting a sprocket to the steering shaft.

3.5 Typical Constellation Drive Installation

Step-by-step guide for mounting the Constellation drive and aligning sprockets.

3.6 Bavaria Drive Installation

Procedure for installing the Bavaria drive, including chain disconnection and mounting.

Drive Chain Installation Steps

Instructions for assembling drive chains, drive adjustment, and chain tensioning.

3.7 Mamba Drive Installation

Steps for installing the Mamba drive, including parts, mounting, and gearbox connection.

3.8 Cobra Drive Installation

Procedure for mounting the Cobra drive unit within the Integra Pedestal.

3.9 Final Checks All Models

Comprehensive checklist for final verification of installation and system functionality.

4- Electrical Wiring

4.1 General Wiring Principles

General guidelines for insulated wiring, polarity, overload protection, and cable standards.

4.2 Electric Cable Selection

Recommendations for selecting appropriate electric cable sizes based on cable run length.

4.3 Electrical Wiring Steps

Instructions for connecting the Integra drive motor and clutch to the course computer.

4.4 Electrical Wiring for Raymarine SPX10

Specific wiring instructions for connecting the drive to a Raymarine SPX10 course computer.

5- Servicing

Regular Maintenance Checks

Routine checks for connections, mountings, chain, sprockets, and cables.

5.1 Integra Bavaria & Constellation Dimensions

Dimensional specifications for Integra Bavaria and Constellation drive units.

5.2 Integra Mamba Dimensions

Dimensional specifications for Integra Mamba drive units.

5.3 Spares

List and identification of available spare parts for the autopilot drives.

5.4 Bavaria & Constellation Drive Specifications

Detailed specifications for Bavaria and Constellation drive units, including power, voltage, and load.

6- Warranty

Limited Warranty Terms and Conditions

Details of the three-year limited warranty, conditions, limitations, and exceptions.

Warranty Exceptions and Exclusions

Specific product categories or conditions excluded from the standard warranty coverage.

Liability, Procedure, and Legal Rights

Information on liability, claims procedure, governing law, and consumer rights.

Summary

1- Introduction

Product Support

Information on obtaining technical assistance and locating distributors worldwide.

CE Approvals

Details on how to obtain CE approval certificates for Lewmar products.

Important Information About This Manual

Guidance on understanding safety and product damage warnings within the manual.

2- Safety Notice

General Safety Warnings

Critical precautions for safe operation, hazard avoidance, and manual control readiness.

EMC Recommended Guidelines

Guidelines for ensuring optimal Electromagnetic Compatibility performance during installation.

3- Installation

3.1 Overview of Drive Kits

Introduction to different autopilot drive kits: Bavaria, Mamba, and Cobra.

3.2 Preparation and Mounting

Guidance on preparation, general position, environment, and structural strength for installation.

3.3 Optional Rudder Reference Unit Setup

Procedure for setting the optional rudder reference unit potentiometer to its midpoint.

3.4 Constellation Chain and Sprockets

Details on chain size, sprocket selection, and installation for Constellation drives.

Sprocket for Steering Shaft

Instructions for selecting and fitting a sprocket to the steering shaft.

3.5 Typical Constellation Drive Installation

Step-by-step guide for mounting the Constellation drive and aligning sprockets.

3.6 Bavaria Drive Installation

Procedure for installing the Bavaria drive, including chain disconnection and mounting.

Drive Chain Installation Steps

Instructions for assembling drive chains, drive adjustment, and chain tensioning.

3.7 Mamba Drive Installation

Steps for installing the Mamba drive, including parts, mounting, and gearbox connection.

3.8 Cobra Drive Installation

Procedure for mounting the Cobra drive unit within the Integra Pedestal.

3.9 Final Checks All Models

Comprehensive checklist for final verification of installation and system functionality.

4- Electrical Wiring

4.1 General Wiring Principles

General guidelines for insulated wiring, polarity, overload protection, and cable standards.

4.2 Electric Cable Selection

Recommendations for selecting appropriate electric cable sizes based on cable run length.

4.3 Electrical Wiring Steps

Instructions for connecting the Integra drive motor and clutch to the course computer.

4.4 Electrical Wiring for Raymarine SPX10

Specific wiring instructions for connecting the drive to a Raymarine SPX10 course computer.

5- Servicing

Regular Maintenance Checks

Routine checks for connections, mountings, chain, sprockets, and cables.

5.1 Integra Bavaria & Constellation Dimensions

Dimensional specifications for Integra Bavaria and Constellation drive units.

5.2 Integra Mamba Dimensions

Dimensional specifications for Integra Mamba drive units.

5.3 Spares

List and identification of available spare parts for the autopilot drives.

5.4 Bavaria & Constellation Drive Specifications

Detailed specifications for Bavaria and Constellation drive units, including power, voltage, and load.

6- Warranty

Limited Warranty Terms and Conditions

Details of the three-year limited warranty, conditions, limitations, and exceptions.

Warranty Exceptions and Exclusions

Specific product categories or conditions excluded from the standard warranty coverage.

Liability, Procedure, and Legal Rights

Information on liability, claims procedure, governing law, and consumer rights.

Overview

The Lewmar Autopilot Drive is a product designed to assist in the general operation of a vessel, providing an autopilot function for steering systems. It is available in several configurations, including Bavaria & Constellation, Mamba, and Cobra drives, each tailored for specific steering system types.

Function Description:

The Autopilot Drive integrates with a vessel's steering system to provide automated steering control. It works by driving a sprocket or directly coupling to a gearbox, depending on the model, to manipulate the rudder. The system is designed to maintain a set course, reducing the need for constant manual helming. An optional rudder reference unit can be integrated to provide feedback on rudder position, enhancing steering accuracy. The drive unit includes a motor and a clutch, which are electrically controlled by a course computer.

Important Technical Specifications:

The manual details various models with specific technical data. All models listed operate with a power output of 0.186 KW (1/4 HP).

  • Voltage: Available in 12V and 24V configurations.
  • Maximum Output Speed: 169 rpm.
  • Maximum Load: 125 ft lbs (10 Nm).
  • Average Current Consumption:
    • 12V models: 6A
    • 24V models: 3A
  • Motor Circuit Breaker:
    • 12V models: 16A
    • 24V models: 10A
  • Clutch Circuit Breaker:
    • 12V models: 3A
    • 24V models: 2A
  • Weight: Ranges from 8.5 kg (13.7 lb) to 10 kg (16.7 lb) depending on the model.
  • Max Boat Size: All models are rated for boats up to 60 ft (16.7 m) or 45 ft (13.7 m) depending on the model.
  • Cable Sizing for Length of Cable Run (from battery):
    • Up to 2m: 6 mm²
    • Up to 40ft (approx. 12m): 10 AWG
    • 4m: 10 mm²
    • 41-66ft (approx. 12.5-20m): 8 AWG
  • Dimensions:
    • Integra Bavaria & Constellation: Length 275mm, Height 149mm, Width 80mm.
    • Integra Mamba: Length 225mm, Height 184mm, Width 60mm.

Usage Features:

  • Installation Flexibility: Mamba drives can be installed in any orientation directly onto the mounting flange of a bevel head or reduction gearbox. Cobra drives retrofit directly into Integra Pedestals. Constellation/Bavaria drives require mounting on a solid structure, potentially requiring a custom frame.
  • Sprocket and Chain System (Constellation/Bavaria): Utilizes a chain kit (5/8" pitch) and sprockets to connect to the steering shaft. The drive sprocket has a 5mm square key for secure attachment. Sprocket sizes are determined by the number of steering shaft turns from hard over to hard over, ensuring optimal steering performance.
  • Direct Coupling (Mamba/Cobra): These drives directly couple to the steering system via a splined output shaft of a bevel-head or gearbox, or integrate directly into the pedestal.
  • Rudder Reference Unit (Optional): If installed, the potentiometer for rudder referencing must be set to the middle point of its total range (5 turns from either stop) during installation, aligning white marks on pulleys and brackets.
  • Adjustable Chain Tension (Constellation/Bavaria): Chain tension can be adjusted using a turnbuckle to minimize lost motion and optimize steering performance. Over-tensioning should be avoided as it can diminish drive performance and manual helming feel.
  • Electrical Connections: The drive has separate electrical connections for the motor (two single-core cables, twisted, sleeved Black (+) and Blue (-)) and the clutch (two-core cable, Black (+) and White (-)). These connect to the course computer, with specific wiring instructions provided for Raymarine SPX10 systems.
  • Safety Features: Circuit breakers are required for both the motor and clutch circuits, positioned close to the battery in a dry, accessible location. These breakers must be manually resettable.

Maintenance Features:

  • Regular Checks:
    • Ensure all connections and mountings are secure.
    • Verify chain and sprockets are correctly aligned and tensioned (for chain-driven models).
    • Lightly grease chain and sprockets.
    • Check cables for signs of wear or damage.
  • Pre-installation Grease: A smear of grease on the drive output shaft is recommended before installation.
  • Warning for Moving Parts: Users are warned to keep clear of moving steering systems at all times and to protect moving parts from access during normal use.
  • Warning for Hot Motors: Electric motors become hot during and for some time after use, requiring caution.
  • Spares: Lewmar provides specific spare kits, including:
    • Constellation sprocket Kit (89300212)
    • Gear Kit (89300211)
    • Shimmed clutch kits (12V - 89300213, 24V - 89300215)
    • Motor kits (12V - 89300210, 24V - 89300214)

The product is designed for the marine environment and comes with a three-year limited warranty for normal private pleasure boat usage, with specific exceptions and conditions for certain parts and commercial applications. It emphasizes the importance of correct installation and maintenance for optimal performance and safety.

Lewmar Integra Autopilot Drive Specifications

General IconGeneral
BrandLewmar
ModelIntegra Autopilot Drive
CategoryMarine Equipment
LanguageEnglish

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