Raymarine SmartPilot X5 woes

[March]

Hello, everyone!
Have had the Raymarine SmartPilor autopilot for about 6 years now. Even though I had some issues setting it up (the color coded cables to the computer were reversed--if you can believe that: made in Hungary, huh!) it took us with no problems to the Bahamas, working continuously and without a hitch for 30+ hours at the time. (After two more days, it popped a fuse, but we got it back and... no problem.) I was so happy to have "Ray" as part of the permanent crew!

However, last summer Ray starting complaining it didn't have enough juice. I was puzzled: bank of two 12 V batteries were brand new. Solar panels were pumping at 160W. Okay, I disconnected it, but then later, Ray's tubular motor started heating up real bad in the Apostle (within 45 minutes, you couldn't hold it in your hand...) We dismantled the "donut," examined the belt (looked brand new) wash it in fresh water... next day, everything was fine. But two days after, it started heating again. And so it went for a whole month: at times, it would work for hours on end, but then the next time, Ray would either complain "not enough power" or simply over-heat within minutes

When disengaged, the wheel turns smooth as butter (I tightened all the rudder connections, so that the autopilot would not chase its own tails and go to-and-fro needlessly)

Try to contact Raymarine. They have been giving me the runaround for three weeks now: the technical support goes, "Sure! We can fix it easily!" but when I try to schedule a technical ticket, the other end of the line goes, "Why don'tcha try other services (and they gave me two phone numbers that service only computers...) I got back to the initial technical support -- and guess what? The technician's excuse was "I am from the UK" and then refused to answer my messages altogether, in true British stiff-lip fashion.

Anyways. I don't want to buy a whole new half-donut with actuator (motor). It's over $500.00 for something that seems like an easy fix to me.

Any ideas? Thank you in advance!

Beginning to lose faith in Raymarine.......

[Neo]

I have an X5 but not used much, so far .... I believe it's a discontinued product so no wonder support is bad.
I assume you are talking about the two motor wires that were in reverse?... not the Fluxgate compass or Pilot Controller wires?
Where are you getting the "not enough power" warnings from? .... the Pilot Controller?

A hot motor might indicate a high current draw by the motor .... Possibly because the voltage to the Wheel Drive Unit (half-donut) is not high enough (as per warning) .... With a digital multi meter have you measured the voltage going to the Wheel Drive Unit (controller end) while it's steering?... Have you measured the current being drawn by the Wheel Drive Unit (controller end) while it's steering?
Have you used the cables that were supplied with the X5?
Have you checked for corrosion on the controller terminals supplying the Wheel Drive Unit?
Is your controller mounted in an always dry (zero or minimal condensation) location? .... or do you have it under the seats/rear berth?

Not sure how familiar you are with marine/auto electrics because this might be a tough nut to crack over a forum... especially a forum that does not specialize in the X5's or has no insight into your electrical setup.

I have uploaded the Service Manual which includes a few diagnostics flow charts that might help .... To download simply enter the Flip-ID 9a8b on www.flip-transfer.com/download ... please confirm you got this Ok?

[March]

Thank you, Neo.
The two color-coded reversed wires were the ones that go into the computer (not sure where they come from, but they were originally color-coded and I had followed the diagram religiously). Most probably from the motor itself. The fluxgate compass showed the right direction, as far as I can remember

I did not measure the current going into the motor while sailing--that would have required gerry-rigging the plug, or disconnecting it from the motor. I simply assumed, like you did, that it was attempting to draw too much power--hence, the overheating. The "Not enough power" message appeared on the pilot controller.

Checked for corrosion and condensation--everything looked fine. I used the original cables

I guess there must be a mechanical glitch somewhere in the donut itself. The clutch has two positions (one is half-way, the other one all the way to the end). For the life of me, I couldn't figure out why: half-way engaged still works just like the full-way does. The manual never mentions the two positions.
Okay, if for some reason the motor happens to get partially jammed (maybe because the clutch is is wobbly, even though it doesn't seem so, as far as I could tell, or maybe because the belt is missing a notch which, again, doesn't look like) then the motor requires MORE power to dislodge it and go past this dead point--which it eventually does). The additional power shows either on the controller, or in over-heating. At times, the motor works smoothly if it happens to click in the right position--but it doesn't last.

[Chinook]

I had a problem with my Smart Pilot a couple of years ago. When I turned it on, it simply didn't work. After confirming that I was getting power to the drive motor, I concluded that the motor had failed. It took a bit of doing before I found a technician who confirmed that the correct replacement motor was still available. I ordered one, put it in, and I was back in business. Not that hard to change out the motor. I dug into the old one and found lots of ground up black stuff. It had obviously stripped out. They told me that the motor does have a limited life span.

[Neo]

March ... you seem to be focused on mechanical issues rather than electrical issues ... which doesn't seem right to me considering with the information you've provided.... Did you download the file I sent?

My guessing when is says "Not enough Power" it means not enough voltage .... As current is harder to measure.
There are ways to operate the motor/drive unit without being at sea.... Do you have the user manual?
Is there any way you could seek the expertise of an electrical technician/engineer?

It took a bit of doing before I found a technician who confirmed that the correct replacement motor was still available. I ordered one, put it in, and I was back in business.

Yes the motor looks too light for the job... So for my future reference to do you know the part number or have any other sourcing information that you could share?

[March]

No, I haven't bee able to download the file. If I click on the link, it goes. "file does not exist"

The message is "low battery" (I think...) which is absurd--like I said, I have a brand-new two house battery bank and they were both fully full

The motor is indeed too light for the job. I''ve heard that before from other sources. Problem is, there seem to be several models ranging in price from $50 to $80 and I don't know which one to order

[Neo]

Ok you can download the manual here [now removed]
This link will only work for the next 24 hours.

Hope it helps

[March]

Thanks. Neo! I'll give it a shot--step by step.
Winter's long enough for that

[Neo]

Good luck March

[Neo]

It took a bit of doing before I found a technician who confirmed that the correct replacement motor was still available. I ordered one, put it in, and I was back in business.

Hi Chinook, any chance of getting that part number or any other sourcing information for the motor?