ComNav 1101 User manual

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
MARINEMARINE
1101/1201 Autopilot System
Technical Manual
Version 1.0

TABLE OF CONTENTS
1. 1101/1201 GENERAL SPECIFICATIONS........................................................................................ 3
2. TROUBLESHOOTING....................................................................................................................... 4
2.1 PROBLEMS DURING INITIAL DOCKSIDE SETUP:................................................................................ 4
2.2 CIRCUIT BOARD REPAIRS:............................................................................................................... 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 PN 82888 REV. 2 (2 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
FOR 1101: PN 82888 REVISION 3 (1 PCB VERSION) ..................................................................................... 9
FOR 1201: PN 83747 REVISION 1 (1 PCB VERSION) ..................................................................................... 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 REMOVING CONNECTORS FROM THE SPU..................................................................................... 12
4.2 REMOVING THE BACK SHELL TO VIEW THE WIRES ......................................................................... 13
4.3 HEAD TO SPU ............................................................................................................................... 14
4.4 DISTRIBUTION BOX TO SPU.......................................................................................................... 15
4.5 COMPASS AND SERIAL DATA CONNECTIONS TO SPU.................................................................... 16
5. DEALERS TEST BENCH................................................................................................................. 17
6. FINAL TEST PROCEDURE ............................................................................................................ 18
7. APPENDIX A...................................................................................................................................... 21
7.1 PROBLEM SOLVING GUIDE FORM.................................................................................................. 21
8. APPENDIX B...................................................................................................................................... 22
8.1 SPU DRAWINGS/SCHEMATICS FOR 82888 REV 2, (2 PCB VERSION)............................................ 22
8.1.1 Processor Board (B Board)...................................................................................................... 22
8.1.2 Backplane Board (C Board)..................................................................................................... 22
9. APPENDIX C...................................................................................................................................... 23
9.1 SPU DRAWINGS 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

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10. APPENDIX D.................................................................................................................................. 24
10.1 DISTRIBUTION 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 TEST BENCH WIRING DIAGRAM.................................................................................................... 25

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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)
(3 inches (76 mm) required behind unit for cabling)
Weight of Signal Processing Unit: 2.2 lbs (1 Kg)

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2. Troubleshooting
In order to isolate the problem quickly it always helps to have as much relevant data as possible
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 Problems during initial 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 voltage 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 blown, check the polarity of Power input cable, making sure
the battery positive goes to the terminal marked POS. and the Battery negative goes to the
terminal marked GND. Replace the blown fuse.
B. Autopilot displays Redo Rudder Setup
1. With the unit in STBY mode, measure the feedback signal for the voltage between 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 pilot off and then performing 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 process of replacing components. 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, especially while repairing a circuit board. This consists of a grounded mat
for working on, the use of a soldering iron with a grounded tip and the wearing of a grounded
wrist strap. Failure to observe these procedures could cause additional damage to the 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 desoldering, we recommend using a vacuum desoldering
tool such as a "Soldapult." Heat the joint until the solder is molten, if necessary adding a little
fresh solder, and then place the tip of the desoldering tool over the joint and activate it. If the joint
is not completely cleaned (you should be able to see through the hole), then resolder the joint and
try again. NEVER use the desoldering tool twice without resoldering the joint in between. When
all the pins of the device to be removed are desoldered, free them by wiggling with a pair of pliers
or an "Exacto" knife. Properly done, you should then be able to lift out the device by hand. Insert
the new device, and resolder carefully, making sure that each joint is fully soldered.

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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 face-plate provide comprehensive yet easy-to-use inputs to the 1101/1201
SPU. A sixteen position rotary switch also allows a user to have effective “hands-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 via either the HEAD port or
the REMOTE port on the SPU.
The 1101 (1201) Control Head receives a data clock from the SPU for clocking out the serial data
as well as clocking in serial data from the REMOTES.
Display data is received with the display clock from the SPU and is processed for display on the
LCD display on the face-plate of the Control Head. Light Emitting Diodes (LED) behind the LCD
provide backlighting.
3.1.2 Disassembly/Re-Assembly
In general it is not recommended that a dealer disassemble the Head unit. Special precautions
are taken at the factory to seal the unit.
NOTE:
IF THE 1101 or 1201 CONTROL HEAD IS DISMANTLED IT WILL NOT BE COVERED UNDER
WARRANTY.
3.1.3 Button Replacement:
If one of the buttons is sticking, gently remove it from the gasket with a knife / small screwdriver.
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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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 refers to the 1101 SPU 82888 Revision 2, which consists of two boards. The 1101
SPU 82888 Revision 3 or higher consists of only one board and is covered in the next section.
The first one is the Processor board, which includes the microprocessor, EPROM and RAM and
the second one is the Backpanel board, which includes the connections to the distribution box,
the Head, the Auxiliary Head and the Compass and the Drive circuitry for a solenoid system.
You can find the schematics for the two boards in the 1101 SPU Rev.2 in Appendix B and for the
Distribution board in Appendix E.
Appendix B includes the 1101 Rev. 2, SPU Boards (2pcbs) – Processor PCB (B board),
and the Control board (C board).
Appendix E is the Distribution Board - Terminal connections and RAI interface circuitry.
ComNav
AUTOPILOTS

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3.2.2 Disassembly/Re-assembly (2 pcb version)
Disassembly:
Disassembly of the 1101 SPU is a straightforward process. First remove the two Phillips screws
from the rear of the autopilot and pull off the rear cover. Remove the four screws that secure the
chassis to the front cover. Carefully separate the front cover from the chassis. The 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 disconnect the ribbon
cable, gently separate the connector on the end of the ribbon cable from the jumper on the
processor board. Use a screwdriver to gently pry the two apart if necessary. 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 disassembly. Reapply Silicone to secure the second 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 Control Head is pressed, it drives the OFF/ON
line low, causing the Power circuitry in the SPU to turn the 5 volts line on, turning
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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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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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, EPROM and RAM, and the support circuitry and connectors to the distribution
box, the Head, the Compass, the Serial Data output, the Auxiliary Head, and the Drive circuitry
for a solenoid system. Note that the boards are the same for 1101 or 1201 but the E-PROMS are
different.
You can find the schematics for the 1101/1201 (1 pcb) SPU in Appendices D.
Appendix D is the 1101/1201 SPU Board - Microprocessor, PROM and RAM, connectors
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 straightforward process. First remove
the two Phillips screws from the rear of the autopilot and pull off the rear cover. Remove the four
screws which secures the chassis to the front cover. Carefully separate 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.