ComNav 1101, 1201 Technical Manual

MARINEMARINE

1101/1201 Autopilot System

Comnav Marine Ltd. #15 – 13511 Crestwood Place, Richmond, BC, Canada V6V2G1 Document PN 83668
Tel: [phone] Fax: [phone]
World Wide Web: www.comnavmarine.com E-mail: comnav@comnavmarine .com

Technical Manual

Version 1.0

TABLE OF CONTENTS

1. 1101/1201 GENERAL SPECIFICATIONS........................................................................................ 3

2. TROUBLESHOOTING....................................................................................................................... 4

2.1 P

2.2 C

ROBLEM S DURING INITIAL DOCKSIDE SETUP

IRCUIT BOARD REPAIRS

:............................................................................................................... 4

:................................................................................ 4

3. CIRCUIT DESCRIPTION.................................................................................................................. 5

3.1 HEAD............................................................................................................................................. 5

3.1.1 General Description:.................................................................................................................. 5

3.1.2 Disassembly/Re-Assembly.......................................................................................................... 5

3.1.3 Button Replacement:................................................................................................................... 5

3.2 1101 SPU

82888 REV. 2 (2

PN

PCB VERSION

)................................................................................ 6

3.2.1 General Description:.................................................................................................................. 6

3.2.2 Disassembly/Re-assembly (2 pcb version).................................................................................. 7

3.2.3 Signals to and from the Distribution Unit ..................................................................................7

3.2.4 Signals to and from the Control Head........................................................................................ 7

3.2.5 Signals to and from the Compass............................................................................................... 8

3.2.6 Signals to and from the Remotes ................................................................................................ 8

3.3 1101/1201 SPU............................................................................................................................... 9

F

1101:

OR

F

1201:

OR

82888 R

PN

83747 R

PN

EVISION
EVISION

3 (1

PCB VERSION

1 (1

PCB VERSION

) ..................................................................................... 9

) ..................................................................................... 9

3.3.1 General Description:.................................................................................................................. 9

3.3.2 Disassembly/Re-assembly (1 pcb version).................................................................................. 9

3.3.3 Signals to and from the Distribution Unit ..................................................................................9

3.3.4 Signals to and from the Control Head...................................................................................... 10

3.3.5 Signals to and from the Compass............................................................................................. 10

3.3.6 Signals to and from the Remotes .............................................................................................. 10

3.3.7 Signals from the SERIAL DATA Output................................................................................... 11

4. CONNECTIONS ................................................................................................................................ 12

4.1 R

4.2 R

4.3 H

4.4 D

4.5 C

EMOVING CONNECTORS FROM THE
EMOVING TH E BACK SHE LL TO VIEW THE WIRES
EAD TO
ISTRIBUTION BOX TO
OMPASS AND SERIAL DATA CONNECTIONS TO

SPU ............................................................................................................................... 14

SPU.......................................................................................................... 15

SPU..................................................................................... 12

......................................................................... 13

SPU.................................................................... 16

5. DEALERS TEST BENCH................................................................................................................. 17

6. FINAL TEST PROCEDURE............................................................................................................ 18

7. APPENDIX A...................................................................................................................................... 21

7.1 P

ROBLEM SOLVING GUIDE FORM

.................................................................................................. 21

8. APPENDIX B...................................................................................................................................... 22

8.1 SPU D

RAWINGS/SCHEMATICS FOR

82888

2, (2 PCB V

REV

)............................................ 22

ERSION

8.1.1 Processor Board (B Board)...................................................................................................... 22

8.1.2 Backplane Board (C Board)..................................................................................................... 22

9. APPENDIX C...................................................................................................................................... 23

9.1 SPU D

RAWINGS AND SCHEMATICS FOR

82888

REV

. 3

AND

83747 (1

PCB VERSION

) ................... 23

9.1.1 Bill of Materials........................................................................................................................ 23

9.1.2 Board Layout............................................................................................................................ 23

9.1.3 Schematic.................................................................................................................................. 23

1101/1201 Technical Manual

10. APPENDIX D.................................................................................................................................. 24

10.1 D

ISTRIBUTION BOX DRAWINGS AND SCHEMATICS

........................................................................ 24

10.1.1 Bill of Materials.................................................................................................................... 24

10.1.2 Board Layout........................................................................................................................ 24

10.1.3 Schematic.............................................................................................................................. 24

11. APPENDIX E.................................................................................................................................. 25

11.1 T

EST BENCH WIRING DIAGRAM

.................................................................................................... 25

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1101/1201 Technical Manual

1. 1101/1201 General Specifications

The Specifications for the 1101/1201 Autopilot Systems define the basic capabilities and
operational limits of the equipment. These are as follows:

Operating Voltage: 10 VDC to 30 VDC

For use with 12 or 24 VDC Battery Systems

Operating Current: 250 mA nominal at 12VDC, tested in STANDBY

MODE. No external devices energized

Operating Temperature Range: 5° to 140° F (-15 to +60° C)
Heading Resolution: 0.25 Degrees
Heading Accuracy: ± 2.0 Degrees
Course Set Resolution: 1.0 Degrees
PORT/STBD Output Type: Open Collector, 3 Amps Max.
Speed Control Output: 2.50 VDC for No Movement

5.00 VDC for Maximum Speed to Port

0.0 VDC for Maximum Speed to Starboard
(10K ohm Source Impedance)

Navigation Input: NMEA 0183 (4800 BAUD):RMA, RMB, RMC, APB

APA, XTE, BOD, WBD, HSC, VBW, VHW, VTG

Navigation Outputs: NMEA 0183 (4800 BAUD):APHDG.

TTL level, Serial Clock and Data

Rudder Angle Indicator Output: 2.5 mA max
Size of Control Head
Width: 7 inches (178 mm)
Height: 3 5/8 inches (92 mm)
Depth: 1 3/8 inches (35 mm)

(1 ½ inches (76 mm) required behind unit for cabling)

Weight of Control Head: 1 lbs (450 gm)

Size of Signal Processing Unit
Width: 8.25 inches ( 210 mm)
Height: 3.75 inches ( 95 mm)
Depth: 2.25 inches ( 57 mm)

Weight of Signal Process ing Unit: 2.2 lbs (1 Kg)

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(3 inches (76 mm) required behind unit for cabling)

1101/1201 Technical Manual

2. Troubleshooting

In order to isolate t he problem quickl y it always helps to have as m uch relevant data as poss ible
about the vessel and its’ accessories. The Problem Solving Guide Form (see Appendix A) can be
used to compile all the necessary information together.

**If an alarm occurs, the Error Checking section in the users manual should be consulted.**

2.1 Probl ems during i nitial Dockside Setup:

A. Autopilot does not turn on

1. Check for power in the Distribution box terminals labeled POS and GND for correct
voltage. This volt age should be the same as the voltage across the terminals on your
batteries.

2. Make sure the main plug is properly plugged into the back of the Autopilot receptacle
labeled “Distribution Box”

3. Check the Fuse. If the fuse is bl own, check the polarit y of Power input cable, m aking sure

the battery positive go es to the terminal m arked POS. and the Battery negativ e goes to the
terminal marked GND. Replace the blown fuse.

B. Autopilot displays Redo Rudder Setup

1. W ith the unit in STBY mode, measure the feedbac k signal for the voltage bet ween the
terminal marked +5V and POS’N in the Distribution box . When rudder is in Dead Ahead
position you should read 2.5 Volts.

2. Check that the Rudder Follower Arm is above the cable gland when rudder is Dead
Ahead.

3. Check for continuity of Rudder Feedback cable. Rectify as necessary and restart the
setup process by switching the p ilot off and then perform ing a full reset. Complete the
dockside setup.

2.2 Circuit Board Repairs:

The circuit boards in the 1101/1201 SPU are delicate, and can be damaged if not handled
properly. The most chance of damage occurs in the proces s of repl ac ing c omponents. Following
the proper procedure as outlined below will minimize the chance of damaging the circuit board.

When handling circuit boards from the 1101/1201 Autopilot you should always use static
prevention measures, espec ially while repair ing a circuit board. Th is consists of a grounded m at
for working on, the use of a soldering iro n with a grounded tip and the wearing of a grounded
wrist strap. Failur e to observe these procedures c ould cause additional damage to t he CMOS
circuitry present on most of the circuit boards.

The best type of soldering iron to use is one with a thermostatically controlled tip. We recommend
using an 800 degree Fahrenheit tip. For desol deri ng, we r ec om mend using a vacuum desoldering
tool such as a "Soldap ult." Heat the joint until th e solder is molten, if necessary adding a little
fresh solder, and then place the tip of the desoldering too l o ver the j o int and ac ti vate it. If the j oint
is not completely cleaned (you should be able to see through the hole), then resolder the joint and
try again. NEVER use th e desolder ing tool twice without resol dering the j oint in between . W hen
all the pins of the de vic e to be removed are d e sold er ed, free them by wiggling with a p air of pli er s
or an "Exacto" knife. Properly done, you should then be able to lift out the de vic e by ha nd. Ins er t
the new device, and resolder carefully, making sure that each joint is fully soldered.

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1101/1201 Technical Manual

3. Circuit Description

3.1 HEAD

3.1.1 General Description:

The 1101 (1201) Control Head provides a convenient user interface. The twelve push-button
user controls on the f ace-plate provide com prehensive yet easy-to-use inputs to the 1101/1201
SPU. A sixteen position rotary sw itch also allows a user to have effective “han ds-on” control of
the Autopilot.

The pushbuttons and rotary switch are interfaced to a microprocessor which, with the built-in
software, sends the appropriate information to the 1101/1201 SPU vi a either the HEAD port or
the REMOTE port on the SPU.

The 1101 (1201) Control Head rec ei ves a dat a c lock from the SPU for cloc king out the serial data
as well as clocking in serial data from the REMOTES.

Display data is received with the d isplay clock from the SPU an d is process ed for displa y on the
LCD display on the face-plate of the Control He ad. Light Em itting Diodes ( LED) behind the LCD
provide backlightin g.

3.1.2 Disassembly/Re-Assembly

In general it is not r ecommended that a dealer disas semble the Head unit. Special prec autions
are taken at the factory to seal the unit.

NOTE:

IF THE 1101 or 1201 CO NTROL HEAD IS DI SMANTLED IT W ILL NOT BE COVER ED UNDER
WARRANTY.

3.1.3 Button Replacement:

If one of the buttons is st icking, gen tly remove it from the gasket with a k nife / sm all screwdriv er.
Remove any burrs from the outside edge of the button. Spray a small amount of SILICON
lubricant on the button and replace into the gasket. Push the button down several times to
remove any air pockets between the gasket and the button.

See Figure 1 on the following page:

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1101/1201 Technical Manual

ComNav

AUTOPILOTS

Figure 1 Removing a Button

3.2 1101 SPU pn 82888 Rev. 2 (2 pcb version)

Note that the 1201 does not come with a 2 pcb SPU version; only the 1 pcb version. See next
section.

3.2.1 General Description:

This section refer s to the 1101 SPU 82888 Re vision 2, which cons ists of two boards. The 1101
SPU 82888 Revisi on 3 or higher consists of on ly one board and is cov ered in the next section.
The first one is the Proc essor board, wh ich includes the microproc essor, EPROM and RAM and
the second one is the Backpanel board, which inc ludes the connections to the d istribution box,
the Head, the Auxiliary Head and the Compass and the Drive circuitry for a solenoid system.

You can find the sch em atics f or the two bo ards i n the 11 01 SP U Rev. 2 in A ppend ix B and f or th e
Distribution board in Append ix E.

Appendix B includ es the 1101 Rev. 2, SPU Boards ( 2pcbs) – Proces sor PCB ( B board),
and the Control board (C board).

Appendix E is the Distribution Board - Terminal connections and RAI interface circuitry.

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1101/1201 Technical Manual

3.2.2 Disassembly/Re-assembly (2 pcb version)

Disassembly:
Disassembly of the 1101 SPU is a straightf orward proces s. First rem ove the two Ph illips scr ews

from the rear of the a utopilot a nd pu ll of f the rear cover . Rem ove t he f our scr ews that secur e th e
chassis to the front c over. Carefully separate the front c over from the chassis. T he two main
boards are connected by a 24 pin header as well as a ribbon cable. The Silicone used to hold one
of the boards should be carefully cut free with an exact-o knife. Carefully separate the two
boards, by pulling them apart to disconnect the header pins. If you need to dis con nec t th e r i bbo n
cable, gently separate the connector on the end of the ribbon cable from the jumper on the
processor board. Use a screwdriver to gentl y pry the two ap ar t if neces s ar y. DO NOT pull on the
cable itself. The E-PROMS can now be replaced or the unit tested on the ComNav Test Bench.

Re-assembly is the reverse of disass embly. Reapply Silicone to secure the sec ond board to the
chassis.

3.2.3 Signals to and from the Distribution Unit

MOTOR F/B Motor Feedback signals from Remotes to the Distribution Unit.
NAV INPUT Signals from a navigation device in the standard NMEA 0183 format.
RUDDER POSITION Rudder position signal from the Rudder follower.
SPEED CONTROL Proportional signal for rudder control.
SHIELD Outer shield of the cable usually grounded to chassis at one end.
BATTERY (+) Battery power (positive side).
SWT POWER OUT The battery power which can be switched off and on by the processor.
PORT OUT “Open collector” signal that controls the rudder to Port. Ground indicates ON.
STBD OUT “Open collector” signal that controls the rudder to Starboard.
RUDDER POWER +5 volts which is supplied to the Rudder Follower.
BATTERY (-) Battery power (negative side).
RUDDER COMMON Ground signal from the Rudder Follower.

3.2.4 Signals to and from the Control Head

OFF/on When the STANDBY switch in the Contr ol Head is pres sed , it dr ives t he OF F/ON

line low, causing the Power circu itry in t he SP U to turn th e 5 volts line o n, tur ning
the Autopilot on.

SD IN All communications to the autopilot are made through the SPI data line. This

data line sends all relevant data from the Head to the SPU.

DISP CLK Clock for SPI data entering the head. This is an SPI clock and should be running

around 1/32 * E-CLK (62.5 KHz)

KEY Clock Clock for SPI data leaving the head. This is an SPI clock and should be running

at around 1/32 * E-CLK (62.5 KHz)
DISP Data SPI Serial Data into the Head from the SPU.
RKEY Data Transfers SPI Serial Data from the Remotes to the Head.

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1101/1201 Technical Manual

PORT Output to tell the head when the rudder is moving Port.
STBD Output to tell the head when the rudder is moving STBD.
ALARM When the buzzer is to sound, the alarm line goes low.
HEAD MODE Line to tell the Interface if it is a Head or a Remote. +5 volts indicates a head,

and 1m ohm resistor to ground indicates a remote.
PWR + 5 Volts.
GND Common.

3.2.5 Signals to and from the Compass

136 KHz P1 Phase 1 Excitation signal to the Compass

13.6 KHz P2 Phase 2 Excitation signal to the Compass.
REFERENCE 2.5 volt reference signal to the Compass.
SINE Sine signal from the Compass.
COSINE Cosine signal from the Compass.
+12 VOLTS Power to the Compass unit.
GND Common ground.

3.2.6 Signals to and from the Remotes

CMD/CTRL Signal used to tell the Remote unit whether it is in control of the system or not.
+5 V + 5 volt power to the Remotes.
DISPLAY CLOCK
ANALOG INPUT
ROTARY SWITCH 0 Signals to tell the SPU which position the Remote rotary switch is in.
ROTARY SWITCH 1 Signals to tell the SPU which position the Remote rotary switch is in.
TURN Signal from the Remote that a Special turn is being initiated.
DODGE Signal from the Remote that a Dodge is being initiated.
PORT P.B. Signal from the Remote that a Dodge or Special turn is to the port direction.
STBD P.B. Signal from the Remote that a Dodge or Special turn is to the starboard .
DISPLAY DATA Data signals that determine what is displayed by the Remote.
GND Common ground.

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1101/1201 Technical Manual

3.3 1101/1201 SPU

For 1101: pn 82888 Revision 3 (1 pcb version)

For 1201: pn 83747 Revision 1 (1 pcb version)

3.3.1 General Description:

The 1101 Revision 3/1201 Revision 1, SPU consists of one board. The board includes
microprocessor, EPRO M and RAM, and the support circ uitry and connectors to the distribution
box, the Head, the Compass, the Ser ial Data output, the Auxiliar y Head, and the Drive circ uitry
for a solenoid system. Note that the boards are th e s ame for 1101 or 1201 but the E- PRO M S ar e
different.

You can find the schematics for the 1101/1201 (1 pcb) SPU in Appendices D.

Appendix D is the 110 1/1201 SPU Board - Micropr oc essor , PROM an d R AM, c onnec tors
to the Head, Distribution box, Compass, NMEA output etc.

Appendix E is the Distribution Board - Terminal connections and RAI interface circuitry

Note: if the 1101 SPU has two boards it is a revision 2. See the previous section.

3.3.2 Disassembly/Re-assembly (1 pcb version)

Disassembly of the 1101/1201 SPU ( 1 pcb version) is a straightfor ward process. First remove
the two Phillips scre ws f rom the r ear of the aut opilot and pul l off the rear c over . Rem ove the four
screws which secures the chassis to the front cover. Carefully separat e the front cover from the
chassis. The E-PROMS can now be replaced or the unit tested on the ComNav Test Bench.

Re-assembly is the reverse of disassembly.

3.3.3 Signals to and from the Distribution Unit

MOTOR F/B Motor Feedback signals from Remotes to the Distribution Unit.
NAV INPUT Signals from a navigation device in the standard NMEA 0183 format.
RUDDER POSITION Rudder position signal from the Rudder follower.
SPEED CONTROL Proportional signal for rudder control.
SHIELD Outer shield of the cable usually grounded to chassis at one end.
BATTERY (+) Battery power (positive side).
SWT POWER OUT The battery power which can be switched off and on by the processor.
PORT OUT “Open collector” signal that controls the rudder to Port. Ground indicates ON.
STBD OUT “Open collector” signal that controls the rudder to Starboard.
RUDDER POWER +5 volts which is supplied to the Rudder Follower.
BATTERY (-) Battery power (negative side).
RUDDER COMMON Ground signal from the Rudder Follower.

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1101/1201 Technical Manual

3.3.4 Signals to and from the Control Head

OFF/on When the STANDBY switch in the Contr ol Head is pres sed , it dr ives t he OF F/ON

line low, causing the Power circu itry in t he SP U to turn th e 5 volts line o n, tur ning

the Autopilot on.
SD IN All communications to the autopilot are made through the SPI data line. This

data line sends all relevant data from the Head to the SPU.
DISP CLK Clock for SPI data entering the head. This is an SPI clock and should be running

around 1/32 * E-CLK (62.5 KHz)
KEY Clock Clock for SPI data leaving the head. This is an SPI clock and should be running

at around 1/32 * E-CLK (62.5 KHz)
DISP Data SPI Serial Data into the Head from the SPU.
RKEY Data Transfers SPI Serial Data from the Remotes to the Head.
PORT Output to tell the head when the rudder is moving Port.
STBD Output to tell the head when the rudder is moving STBD.
ALARM When the buzzer is to sound, the alarm line goes low.
HEAD MODE Line to tell the Interface if it is a Head or a Remote. +5 volts indicates a head,

and 1m ohm resistor to ground indicates a remote.
PWR + 5 Volts.
GND Common.

3.3.5 Signals to and from the Compass

136 KHz P1 Phase 1 Excitation signal to the Compass

13.6 KHz P2 Phase 2 Excitation signal to the Compass.
REFERENCE 2.5 volt reference signal to the Compass.
SINE Sine signal from the Compass.
COSINE Cosine signal from the Compass.
+12 VOLTS Power to the Compass unit.
GND Common ground.

3.3.6 Signals to and from the Remotes

CMD/CTRL Signal used to tell the Remote unit whether it is in control of the system or not.
+5 V + 5 volt power to the Remotes.
DISPLAY CLOCK
ANALOG INPUT
ROTARY SWITCH 0 Signals to tell the SPU which position the Remote rotary switch is in.
ROTARY SWITCH 1 Signals to tell the SPU which position the Remote rotary switch is in.
TURN Signal from the Remote that a Special turn is being initiated.
DODGE Signal from the Remote that a Dodge is being initiated.

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1101/1201 Technical Manual

PORT P.B. Signal from the Remote that a Dodge or Special turn is to the port direction.
STBD P.B. Signal from the Remote that a Dodge or Special turn is to the starboard .
DISPLAY DATA Data signals that determine what is displayed by the Remote.
GND Common ground.

3.3.7 Signals from the SERIAL DATA Output

ADIOS CLK Serial clock.
ADIOS DATA Ser ial data .
NMEA ‘A’ ‘A’ side of NMEA 0183 coded data.
NMEA ‘B’ ‘B’ side of NMEA 0183 coded data.
GND Common ground.

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1101/1201 Technical Manual

4. Connections

4.1 Removing Connectors fr om the SPU.

Figure 2 Removing Connectors

To remove the connectors from the receptacles on the back of the SPU, just squeeze th e finger
grip cross-stripes to f lex t he p las t ic s ides and unlock the tabs. W hile you are squeezing t he s i des
slide the connector off. This is the same for both sizes.

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1101/1201 Technical Manual

4.2 Removing the back shell to view the wires

Figure 3 Cable Assembly

Turn the back shell counter clockwise until it is loose from the connector. Pull the back shell
about 12 inches along the wire. Notice that the strain relief is notched. There are four pegs in the
connector that fit into the notches i n th e s trai n r elief . This connector will not fit together properl y if
those pegs are not in the notches. You can carefully pull the strain relief away from the connector
to expose the wires. The wires can now be checked for proper connection.

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1101/1201 Technical Manual

4.3 Head to SPU

12 Fem ale Pins,
Com Nav P.N. 40214

8

7

2

1

9

6

10

34

5

1211

Plug with Backshell
12 Pin Black
Com Nav P.N. 40844

87

1

2

6

9

5

10

4

3

12

11

26ft (8 meters)

12 +1 conduc tor cable

Com Nav P.N. 83018

View along Arrow
Direction

Figure 4 Head Connector

WIRE COLOUR VIKING

SIGNALS

CONNECTOR

PIN #

BLUE 1 ON/OFF CMND/CTRL

BROWN 2 +5Volts +5 Volts

PINK 3 Display Clock Displa y Clock

RED with BLUE stripe 4 Head Mode

VIOLET 5 Remote Data Rotary Switch “0”

BLACK 6 Key clock Data Turn/Adj

YELLOW 7 Serial Data IN Dodge/Alarm

RED 8 Port Drive Light Port/up

GREEN 9 STBD Drive Light STBD/Down

HEAD

SIGNALS

AUXILARY

STATION

WHITE 10 Display Data Display Data

GREY with PINK stripe &

SHEILD DRAIN

GREY 12 Alarm Rotary Switch “1”

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11 Ground Ground

1101/1201 Technical Manual

4.4 Distribution Box to SPU

Plug with Backshell
12 Pin Black

Com Nav P.N. 40844

12 Fem ale Pins,
Com Nav P.N. 40214

10

9

8

7

1

2

34

1211

6

5

87

1

6

5

4

3

12

11

10ft (3 meter s)
11 +1 conductor cable

92

10

Com Nav P.N. 81747

View along Arrow
Direction

Figure 5 Distribution Box Connector

WIRE COLOUR VIKING CONNECTOR PIN # SIGNAL

GREY with PINK stripe 1 Motor Monitor

VIOLET 2 Nav Signal

RED 3 Rudder Position

BLUE 4 Speed Control

SHIELD 5 Shield (Common to

Battery negative)

YELLOW 6 Battery (+)

GREY 7 Switched Power

PINK 8 Port Out
WHITE 9 STBD Out
BLACK 10 Rudder Power

BROWN 11 Battery (-)

GREEN 12 Rudder Common

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1101/1201 Technical Manual

4.5 Compass and Serial Data connections to SPU

Plug with B ackshell
7 Pin Black

Com Nav P.N. 40830

7 Fem ale Pins,
Com Nav P.N. 40214

40ft (12.3 meters)

2

3

7

1

4

6

5

2

3

7

1

6

4

5

6 +1 c onductor cable
Com Nav P.N. 40858

View along Arrow
Direction

Figure 6 Compass and Serial Data Connector

WIRE COLOUR VIKING

CONNECTOR PIN #

SIGNALS TO/FROM

COMPASS

SIGNALS FROM

SERIAL DATA OUT

BLUE 1 Sine AD-10-S CLK

RED 2 13.6 KHz N/C

BLACK 3 13.6 KHz N/C

SHIELD 4 Ground GND

WHITE 5 Reference NMEA ‘B’

YELLOW 6 Cosine AD-10-S DATA

GREEN 7 +12 Volts NMEA ‘A’

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1101/1201 Technical Manual

5. Dealers Test Bench

DATA

CLOCK

ALARM

SWITCHED POWER
Amps

Main Cable to
1001/1101 Processor

1001/1101
Distribution
Box

SIG

JOG

GREEN

NAV INPUT

RET

FUSE

3 Amps

RED

2001
Distribution
Box

Main Cable
to 2001 Processor

+

12 VDC

-

ON

OFF

WATCH

ALARM

1001/1101

2001

NAV 1

NAV 2

Figure 7 ComNav Test Bench

If you have a Com Nav Test Benc h, an 110 1 or 120 1 ma y be connected to it for testi ng. T his will
help in isolating problems with the 1101 or 1201 SPU. The cable f rom the 1001/1101 D is trib uti on
box in the Test Bench plugs into the SPU. Also connect a Control Head t o the SPU. A com pass
will also be required if any of the SINE, COSINE, FILTER, or compass tests are to be done.
Included in Appendix E is the wiring diagram for the test bench.

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1101/1201 Technical Manual

6. Final Test Procedure

Note: only some of the possible tests are done on the T est Be nch. All of them would n orm all y be
done in the factory Final Test Procedure.

1. ON/OFF Circuitry
Turn the Autopilot ON. Press and Hold the ON/STBY button on the autopilot Head until the

standby status sc reen ( ST BY) comes up on the display. This should tak e abo ut 3 seconds. Turn
the Pilot OFF. The Autopilot should turn off after holding the button do wn until the screen goes
blank. This should take about 2 seconds.

2. +12
Turn on the Autopilot. C lip the voltmeter leads to the +12 V and GND test hoops on the b ack

panel PCB of the SPU. The voltmeter s hould read 12 volts ( ±1.5 volts). The m easured voltage
should not change more than ±0.1 volts for either 12 or 24 volt systems.

3. +5
Clip the voltmeter le ads to the +5V and the GND tes t hoops on the back panel P CB of the SPU .

The voltmeter should read 5.15 volts (±0.15 volts). The m easured voltage should not change
more than ±0.05 volts for a 12 or 24 volt system.

4. +2.5V
For the either PCB version, the voltage between the +2.5V test hoop and the +5V test hoop

should be the sam e as the voltage betwee n the +2.5V test hoop and the GND test hoop ±0.015
volts.

5. STARBOARD
Turn the pilot off. Put a jum per on the Spec ial Test pins of the SPU. Turn th e pilot on. You are

now in a limited special test m ode. Pressing the ri ght DODGE button on th e Head will advance
you into the test, while pressing the left DODGE button will move you back in the test.

Press the right DODGE key until the 5TBD is seen in the bottom right corner of the LCD. At th is
point the STBD (Gree n) LED o n the Dis tribut ion B ox s hould t urn o n. T he Ru dder Angl e In dicat or
(RAI) on the Test Bench should go to starboard. T he signal is heavily dam ped and may take a
few seconds to m ove onto the sca le. T he curren t read ing o n the T es t Bench Amm eter s hould go
to about 2 amps.

6. PORT
Press the right DODGE button until PO RT is seen in t he bottom right corn er of the LCD. At this

point the PORT (Red) LED in the distribution box should turn on. The RAI on the T est Bench
should go to port. The current reading on the Test Bench Ammeter should go to about 2 amps.

7. SWITCHED POWER
Press the right DODGE button until 5PuR is displa yed on the LCD. The Switched Power LED

(SWI PWR) on the Distr ibution box shoul d turn on. Perf orm the load test b y pressing the red or

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green JOG buttons on t he Test Be nch. The current reading on the Test Bench Am meter should
go to about 2 amps.

8. RUDDER SPEED
Press the right DODGE button until R5Pd is displayed in the lower right corner of the LCD.

Check for Rudder Speed sign al on t he D is tr ibuti on box wi th a n osc i ll osc ope. Pic k up a ground on
battery negative and probe th e sc rew term inal f or S PEED. T he signa l sho uld b e a ram p at a bout

2.5 volts repeating at about 100 ms ec.

9. VOLTAGE
Press the right DODGE button u ntil A0xx is displayed in the lo wer right corner of the LCD. A

reading of 31 on the r ight side of the reading indica tes about 12 volts while a r eading of 62 is
about 24 volts.

10. RUDDER FOLLOWER
Press the right DODGE button until A2x x is displayed in the lo wer right corner of the LCD. T he

right side of the readi ng should rea d 7E when the ru dder is cent ered. Read th e rudder angle o n
the Test Bench RAI. T he angl e can be adjus ted b y pressin g the T est Benc h JO G s witches. Us e
the JOG switch to set t he RAI to a bout 40 de grees Starbo ard and ch eck that the right s ide of the
LCD reading is 3E. Check that at about 40 degrees Port, the reading is BE.

11. MOTOR MONITOR
Press the right DODGE button until A3xx is displayed in the lower right corner of the LCD. The

right side of the reading should read 00. Place a 1 00R jumper between term inals marked +5 V
and MOTOR MON in the distribution box. The right side of the reading should now display FF.

12. COSINE
Press the right DODGE button u ntil A6xx is displayed in the lo wer right corner of the LCD. A

properly adjusted KVH or ComNav compass s hould read 7 E o n th e e as t or west, 62 on nor th and
9B on south.

13. SINE
Press the right DODGE butt on until A7xx is displayed in the lower right corner of the LCD. A

properly adjusted KVH or ComNav compass should read 7E on north or south, 62 on east and 9B
on west. Leave the compass reading 7E on north.

14. FILTER
Press the right DODGE button until a four-dig it number is displa yed in the lower right corner of

the LCD. Turn the compass until the num ber reads abo ut 2250. Place a digital voltm eter (DVM)
across the SIN and REF test points. Fine-tune the compass so that the voltage on the DVM
meter reads 0 volts . Adjust the filter pot entiometer on the SPU car d so that 2250 is displayed.
Re-paint the Filter Pot. Turn the Pilot to OFF and remove the Special Test jumper.

15. FLUXGATE COMPASS

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Perform an accuracy test every 20 degrees. Pass if total error is less than or equal to 4 degrees.

16. AUTO ADJUST – ComNav Fluxgate Compass
Place the Fluxgate com pass on a Lazy Susan. Place a m agnet approximately 3 inches away

from the compass at 45 degrees. Perform an auto adjust. Please see the compass
compensation section of the 1101 Operation and Installation manual for further instructions on
compass compensatio n. Perform an accuracy test every 20 degrees. Pass if the total er ror is
less than or equal to 4 degrees.

17. FULL RESET and DOCKSIDE SETUP
Perform a Full Reset and Dockside Setup. Leave the pilot set for a magnetic compass.

18. MAGNETIC COMPASS
Plug a Magnetic compass into the pilot. Select the magnetic compass option in the Dockside

Setup. Adjust Compass adjust to make the autopilot and compass agree. Perform accuracy
tests every 20 degrees . Pas s if total err or is l es s tha n or e qua l to 4 degrees. Reset th e c ompass
adjust to zero.

19. NAVIGATION INPUT
Feed NMEA 0183 Autop ilot sentences into th e 1101 distribution box via the NAV INPUT on the

Test Bench. Turn the pilot on and put into NAV mode. After a few seconds double-press the
NAV key. The type of data being r eceived or the name of the 0 183 data sentences should be
displayed.

20. HEADING OUTPUT (1 pcb SPUs only)

Connect a cable to the H EAD ING O UT PUT connector on the 1101/ 120 1 SPU. Note : that the two
board SPU is not supplied with this connector. Connect the ‘scope ground to the cable shield and
the probe lead to the white wire. Dat a type signals should a ppe ar on the ‘s cope. Similarly, check
the green lead. Check that the blue lead has data clock pulses on it. The yellow lead should have
bursts of data on it.

NOTE:
The Final test procedur e is intended to check all the basic functions of the autopilot. O nce the

unit is re-installed on the v ess el you must go through the d oc k s ide s etup proc e dure and complete
the compass selection and compensation.

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7. APPENDIX A

7.1 Probl em Solving Guide Form

Description of Problem:__________________________________________________________
_____________________________________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________

Compass Type:________________________________________________________________
Feedback Type:________________________________________________________________
Drive Unit Type:________________________________________________________________
Nav Input Type:____________ __ ___ ___ ___ ___ ____________________ ___ ___ __ ___ ___ ___ _
Input Voltage:__________________________________________________________________
Power Source:________ ___ ___ __ ___ ___ ___ ___ ____________________ ___ ____ _ ___ ___ ___
Battery:_______________________________________________________________________
Installation Date________________________________________________________________
Rudder Hard over Time:__________________________________________________________
Number of Rudders_____________________________________________________________
Dealer Name__________________________________________________________________

Additional Information:___________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

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8. APPENDIX B

8.1 SPU Drawings/Schematics for 82888 rev 2, (2 PCB Version)

8.1.1 Processor Board (B Board)

Part # 31130

8.1.1.1 Bill of Materials

8.1.1.2 Board Layout

8.1.1.3 Schematic

8.1.2 Backplane Board (C Board)

Part #31145

8.1.2.1 Bill o Materials

8.1.2.2 Board Layout

8.1.2.3 Schematic

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9. APPENDIX C

9.1 SPU Drawings and Schematics for 82888 rev. 3 and 83747 (1
pcb version)

Part #31158

9.1.1 Bill of Materials

9.1.2 Board Layout

9.1.3 Schematic

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10. Appendix D

10.1 Distri bution Box Drawings and Schematics

Part # 31158

10.1.1 Bill of Materials

10.1.2 Board Layout

10.1.3 Schematic

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11. Appendix E

11.1 Test Bench Wiring Diagram

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