ComNav 1440 User manual

1440/1460 Autopilot Systems
Installation & Operation Manual
COMPLIES WITH
CE REGULATIONS
PN 29010014 V2.3

1440/1460 Autopilot Systems
Installation & Operation Manual
Document PN 29010014 V2.3

First Printing: 1993
Revised: 2004
Revised: January/February & June 2009
Document PN 29010014 V2.3

ComNav Marine 1440/1460 Autopilot Systems
WELCOME Congratulations on your purchase of a ComNav Marine 1440/1460 Autopilot
Systems! At ComNav, we are dedicated to reliability & quality in all our products,
and proud of our prominence as a leader in the design and manufacture of
marine autopilot systems. We promise to do our best to ensure your satisfaction
with your new Autopilot System.
ComNav Marine Ltd.
#15 - 13511 Crestwood Place
Richmond, BC
Canada V6V 2G1
Phone: [phone]
Fax: [phone]
In Canada or the USA
E-Mail: [email protected]
Web Site: www.comnavmarine.com
WARRANTY NOTICE
Prior to the installation and/or operation of the equipment, ensure that you read,
understand, and accept the conditions of the warranties as detailed in the
Warranty Information section of this manual.
OPERATOR’S WARNING
The 1440/1460 Autopilot Systems will steer your vessel, when you activate it.
However, it is only an aid to navigation. Its performance can be affected by
many factors including equipment failure, environmental conditions, and improper
handling or use. An autopilot system does not reduce your responsibility for the
control of the vessel when underway. You must always be in a position to
monitor the course, supervise the autopilot, and resume manual control if the
need to do so arises.
Whenever underway, your vessel must be under the
control of a qualified and alert person.
GENERAL NOTICE
This document, ComNav part number 29010014 Version 2 Revision 2, is the approved
Installation and Operation Manual for use with the 1440/1460 Autopilot Systems. Where
versions of this manual exist in other languages, the English version shall be considered
authoritative.
Document PN 29010014 V2.3 1

ComNav Marine 1440/1460 Autopilot Systems
Document PN 29010014 V2.3 2
This page is intentionally blank.

ComNav Marine 1440 & 1460 Autopilot Systems
TABLE OF CONTENTS
Product Description....................................................................................................................5
Before You Start..........................................................................................................................6
Unpacking and Identification.........................................................................................................................6
Manual Conventions .....................................................................................................................................6
Display...........................................................................................................................................................6
Tools Required..............................................................................................................................................7
Parts List .......................................................................................................................................................9
Installation Instructions ...........................................................................................................13
1440/1460 Autopilot System.......................................................................................................................13
Planning..............................................................................................................................................13
Processor Location ........................................................................................................................13
Compass Location .........................................................................................................................14
Power Connection..............................................................................................................................14
Power Cable...................................................................................................................................14
Grounding ......................................................................................................................................14
1440 Receptacle & Control Head Installation ....................................................................................15
Mounting Clip Installation...............................................................................................................15
1460 Control Head installation...........................................................................................................16
Fluxgate Compass Installation...........................................................................................................17
Rotary Rudder Feedback Installation.................................................................................................18
Outboard Feedback Installation.........................................................................................................21
Rudder Drive...............................................................................................................................................25
ComNav Reversing-Motor Hydraulic Pump .......................................................................................25
Pump Models & Specifications ......................................................................................................26
Specifications Common to All Pumps............................................................................................26
Types of Steering Systems ................................................................................................................27
Tools and Material Required to Install Pump.....................................................................................27
Notes & Cautions ...............................................................................................................................28
Installing the Pump.............................................................................................................................29
Hydraulic Connections .......................................................................................................................30
Fill And Bleed .....................................................................................................................................32
Wiring The Processor .................................................................................................................................35
Right Side Connections......................................................................................................................36
Left Side Connections........................................................................................................................38
Connecting the Ground Wire .........................................................................................................38
Connecting the Navigation Cable ..................................................................................................40
Mounting the Processor .....................................................................................................................41
Powering Up the System....................................................................................................................41
Fuse Replacement.............................................................................................................................42
Setting Up the Autopilot System .................................................................................................................43
Setup Routine.....................................................................................................................................43
Locating the “Flush Key”................................................................................................................44
Setting Up – Step by Step...............................................................................................................45
Fluxgate Compass Compensation.................................................................................................49
Align to Magnetic North..................................................................................................................50
Finishing the Setup.............................................................................................................................50
Document PN 29010014 V2.3 3

ComNav Marine 1440 & 1460 Autopilot Systems
Piloting with the 1440 or 1460 Autopilot.................................................................................51
Turning ON the 1440/1460 Autopilot:.................................................................................................51
Turning the Autopilot OFF..................................................................................................................51
Autopilot Modes ..........................................................................................................................................51
STANDBY MODE....................................................................................................................................51
POWER STEER MODE ...........................................................................................................................51
PILOT MODE.........................................................................................................................................52
NAV MODE ..........................................................................................................................................52
Steering Control Settings............................................................................................................................52
What is Good Steering Control? ........................................................................................................53
Determining the Response Settings ...........................................................................................................53
Setting the Slow Speed Rudder & Counter-Rudder Response Sensitivities.....................................53
Turns and Changing Course..............................................................................................................56
Setting the Fast Speed Rudder Response & Counter- Rudder Sensitivities.....................................57
Fast Speed Turns and Course Changes ...........................................................................................57
Adjusting the Digital Rudder Angle Indicator (RAI).....................................................................................59
RAI Offset...........................................................................................................................................59
The Navigation Interface.............................................................................................................................60
NMEA 0183........................................................................................................................................60
Using the Navigation Interface....................................................................................................................61
Incorrect or No Navigation Data.........................................................................................................61
Cross Track Error...............................................................................................................................62
NAV MODE Display.......................................................................................................................................63
Operation Commands ..............................................................................................................65
Adjustment Commands............................................................................................................67
1440 & 1460 Control Head Messages......................................................................................68
Problems without an Error Code.............................................................................................72
Appendix A................................................................................................................................73
Connections to 4 and 5 Wire Motors..................................................................................................73
Appendix B................................................................................................................................74
Connections to 4 and 5 Wire Motors (using a clutch or lockup valve)...............................................74
Appendix C................................................................................................................................75
Connections to Solenoid Valves ........................................................................................................75
Appendix D................................................................................................................................76
Remote Operation..............................................................................................................................76
Appendix E ................................................................................................................................78
Connecting the NMEA 0183 Heading Output.......................................................................................78
Appendix F ................................................................................................................................79
Connecting a Rudder Angle Indicator................................................................................................79
Warranty ....................................................................................................................................81
CE Compliance..........................................................................................................................85
Document PN 29010014 V2.3 4

ComNav Marine 1440 & 1460 Autopilot Systems
Document PN 29010014 V2.3 5
Product Description
ComNav 1440 & 1460 Autopilot Systems
are reliable, accurate and easy to use
aids to navigation. They feature four
operating modes, watertight design, and
a built-in navigation interface.
When steering along a Course line in NAV
MODE, the 1440/1460 use Heading
information from the compass, and
position information from a a GPS
receiver, a chartplotter, or other device, to
calculate a Course to Steer which will
keep the vessel on the Course line. The four operating modes are:•S
TANDBY MODE allows manual
steering while displaying compass
information. 1440/1460 Autopilots have a feature
called Ghost Rudder. Should the Rudder
Feedback ever fail, the Autopilot will use
its prior knowledge of how the rudder
moves to calculate new “virtual rudder”
positions. While the Ghost Rudder will
not allow the Autopilot to steer as well as
it can with the Rudder Feedback, it will
allow the Autopilot to be used until repairs
can be made.
•POWER STEERING MODE features push
button steering control, and displays
compass or rudder information.
•PILOT MODE steers to a constant
Heading.
•NAV MODE steers along a Course line,
when the 1440/1460 is connected to
an appropriate navigation device.
A Dodge feature is available in both PILOT
and NAV MODES. 1440/1460 Autopilots are protected
against many mishaps, including: reverse
power connection, output circuitry
overload, computer failure, or program
error.
To steer a constant Heading, the
1440/1460 Autopilot compares the
current Compass reading to the Heading
(Course) that the operator has selected.
If the vessel is not on the correct
Heading, the Autopilot calculates the
rudder position which will bring the vessel
onto the correct Heading.
Specifications
Voltage: 10 VDC - 40 VDC
Steering Outputs: 20 Amperes Maximum
Dimensions L x W x H or D
1440 Control: 5.1 x 2.75 x 1.0 inches
The Autopilot uses the vessel’s steering
system (a hydraulic system, or an electric
motor, and mechanical linkage) to move
the rudder (or outboard motor) to the
position it calculates. Information from
the Rotary Feedback (or Outboard
Feedback) is used to calculate new
rudder positions, and to verify that the
steering system has followed the
Autopilot commands.
(13.3 x 7.0 x 2.5 cm)
1460 Control: 3.1 x 6.0 x 1.0 inches
(7.9 x 15.4 x 2.5 cm)
Processor: 15 X 6.3 X 2.7 inches
(38.1 x 16.0 x 6.9 cm)
Compass: 5.6 x 3.0 x 4.2 inches
(14.2 x 10.7 x 7.6 cm)
Pump: 7.5 x 4.75 x 4 inches
(19.0 x 12.2 x 10.2 cm)

ComNav Marine 1440 & 1460 Autopilot Systems
Before You Start
Thank you for buying the ComNav 1440
or 1460 Autopilot System. It will make
boating safer, easier and more enjoyable
for you!
Please do not forget to complete and
send in your warranty card.
This will give you 3 years of Warranty
protection. We suggest that you do it
first!
Happy boating!
Unpacking and Identification
Please make sure that you have found
and identified all of the components of
your Autopilot System, before you begin
installation. This manual begins with a
parts list, to help you identify the
components of your system.
Your system will have either a Rotary
Rudder Feedback or an Outboard Motor
Feedback. There are separate sections
about both Feedback units in this manual.
If you purchased a system without a
Hydraulic Pump, you can ignore the
sections of the manual dealing with
Pumps, and about bleeding the hydraulic
system.
Wiring diagrams for connecting to 4 and 5
wire motors and solenoid valves are in
the appendixes.
Manual Conventions
In this manual, the names of the main
components are capitalized.
For example: Processor.
Also, the keys on the Control Head are
capitalized.
For example: Set Key.
When you are required to perform an
action with a key, it is underlined.
For example: Press the Red Key.
Your ComNav 1440/1460 Autopilot has
four operation modes. They will be
printed as small capitals.
For example: PILOT MODE,
STANDBY MODE.
Display
When the text asks you to look for a
specific message in the display of the
Control Head, the text will show the
display in this way:
rítSt
The box around the image above
represents the frame of the Head’s LCD
display. Because the display is a “Seven
Segment” type, lower case and upper
case letters must often be mixed together
in the LCD display – and so also in the
images in this manual. Sometimes, a
drawing of the display will follow the text.
When a particular display is mentioned in
the text, the “normal English” message
represented by the display will follow.
For example:
rítSt (rudder test)
or HO S (hard over Starboard)
Document PN 29010014 V2.3 6

ComNav Marine 1440 & 1460 Autopilot Systems
Document PN 29010014 V2.3 7
Tools Required
The general tools & other items you will
need while installing the system are:
1) Basic Tool Kit
2) Screwdrivers: One Phillips, one
slot-head
3) Wire Cutters: a pair of ordinary wire
cutters suitable for general electrical
work will do
4) Drill and a selection of Drill Bits
5) Small Adjustable Wrench
6) Any tools specific to your boat
7) Miscellaneous fasteners & mounting
hardware, for mounting components
and securing hydraulic lines (see
individual “installation” sections,
below, for specific suggestions)
8) You may also wish to have a supply
of Ty-wraps (aka “zap straps”) for
securing electrical cables
If you purchased a 1440/1460 with a
Hydraulic Reversing Pump, a list of the
tools you will require specifically for the
installation of the Pump is on page 27.
If you purchased a 1440/1460 with a
Rotary Rudder Feedback, you may need
one stainless steel band clamp, of a size
more than large enough to fit around your
vessel’s rudder post. See page 18.

ComNav Marine 1440 & 1460 Autopilot Systems
1460 System Diagram (with 1440 Second Station)
Document PN 29010014 V2.3 8

ComNav Marine 1440 & 1460 Autopilot Systems
Document PN 29010014 V2.3 9
Parts List
Note: Parts are not drawn to any scale.
Processor. PN 20080003
For 1440 system packages:
1440 Control Head. PN 20080002. This part includes a
flexible curly-cord, with a plug on the far end, wired to it; the
cord can stretch to about 5 foot (1.5 m) long.
1440 Control Head Mounting Clip.
PN 65610010 (this is included in the 1440
Accessory Kit, see page 11).
For 1460 system packages:
1460 Control Head. PN 20080004. This part includes a
25 foot (7.7 meter) cable, labelled “1”, wired to it. A
Mounting Bracket for it, & fasteners, are included in the
1460 Accessory Kit (see page 11).

ComNav Marine 1440 & 1460 Autopilot Systems
ComNav Fluxgate Compass. PN 20320003. This
part includes 40 feet (12.2 m) of cable wired to it.
One Feedback unit or the other will be included:
Rotary Rudder Feedback. PN 20330008. This part
includes 50 feet (15.2 m) of cable wired to it.
This part always comes with:
OR:
Rotary Rudder Feedback
Linkage Kit. PN 20330007.
Outboard Feedback. PN 20330002. This part
includes 30 feet (9.1 m) of cable wired to it.
Document PN 29010014 V2.3 10

ComNav Marine 1440 & 1460 Autopilot Systems
Also included but not shown:
•Power Cable. 7.5 feet (2.3 m) of cable (labelled “5”), for connecting supply voltage
to the Processor.
•Accessory Kit. The 1440 kit (PN 20080005) contains a Mounting Clip for the 1440
Control Head, and some lubricant for the Head’s plug. The 1460 kit (PN 20080006)
contains a mounting bracket & fasteners for the 1460 Control Head. Both kits
contain extra terminal sockets and a cable gland.
•Control Head Interconnection Cable (1440 systems only): 10 feet (3 m) of cable
(labelled “1”), with an attached receptacle (with cap) & a mounting washer.
•1440 & 1460 Installation & Operation Manual (this manual, PN 29010014).
If you purchased a system with a hydraulic pump, one of two models of pump, and at one
of two operating voltage ratings, will be included. All pumps look very similar, so inspect
the labels carefully.
•18CI Reversing Pump, 12 VDC. PN 20810016
•18CI Reversing Pump, 24 VDC. PN 20810031
•30CI Reversing Pump, 12 VDC. PN 20810018
•30CI Reversing Pump, 24 VDC. PN 20810035
All pumps have 20 feet (6.1 m) of cable wired to the
Pump Motor.
If you purchased a system with a Cable Drive, one of several models will be included. The
models vary slightly in appearance, so inspect the labels carefully.
•Type 'S' (Morse Straight Shaft – shown in the figure).
PN 20910002
•Type 'MTS' (Morse Tilt Shaft). PN 20910003
•Type 'T' (Teleflex Performance Tilt). PN 20910004
•Type 'TST' (Teleflex Standard Tilt). PN 20910005
•Type 'R' (Remote). PN 20910009
Document PN 29010014 V2.3 11

ComNav Marine 1440 & 1460 Autopilot Systems
Plugging the 1440 Control Head curly-cord cable into the socket on Cable #1
1460 Control Head with attached Cable #1
Document PN 29010014 V2.3 12

ComNav Marine 1440 & 1460 Autopilot Systems
Document PN 29010014 V2.3 13
Installation Instructions
Caution
Using ordinary electric tools near water is VERY dangerous! To minimize the dangers
of electric shock and personal injury, we recommend using cordless rechargeable tools
or hand tools.
1440/1460 Autopilot System
Planning
Processor Location
In choosing a location for your ComNav
1440 or 1460 Autopilot System, please
note that the cable from the Control Head
to the Processor (cable #1) should not be
cut or extended. Excess cable may be
loosely coiled behind a panel.
For the 1460:
- cable #1 is 25 feet (7.7 m) long, and
is permanently attached to the
Control Head. See the figure on the
previous page.
You will want to have the Control Head
near the steering station you use the
most. So, you should also note the
following, when routing cable #1:
Similarly, the cable from the Compass to
the Processor (Cable #2), should not be
cut or lengthened. Cable #2 is 40 feet
(12.2 m) long (excess may be coiled up).
For the 1440: Allow at least a foot (30 cm) of clearance
on either end of the Processor in the
space where it is to be located.
- Cable #1 is 10 feet (3 m) long, and
ends in a socket receptacle.
- the curly-cord cable from the 1440
Control Head has a plug on the end,
which is plugged into the socket on
the end of Cable #1 (see the figure
on the previous page).
Do not mount the Processor near heat
sources, such as heat radiators, or over
engines.
If you can, mount the Processor so that
the cooling fins are vertical.
- place the 1440 Control Head’s
Mounting Clip at the most-often
used station, so that you have a
“normal” position for the Control
Head.
If possible, mount the Processor where
you will be able to hear its internal beeper
while operating your boat. Although the
lights on the Control Head will tell you
about the Autopilot's actions, it helps if
you can hear the beeper too.
- try to position the Processor and
Cable #1’s socket end so that the
1440 Control Head will also be
useable in any other places where
you will want to be when using the
Autopilot, without over-stretching the
curly-cord.

ComNav Marine 1440 & 1460 Autopilot Systems
Compass Location
When choosing a location for the
Compass, try to locate it as close as
possible to the most stable spot on your
boat. Usually this spot will be close to the
waterline level, in the middle of the boat
and two-thirds towards the stern from the
bow.
Do not install your Compass near wires or
devices carrying large electric currents,
such as battery chargers, electric pumps
and motors or televisions.
Do not mount your Compass near any
iron or steel objects.
Power Connection
There is 7.5 feet (2.3 m) of power cable
included with your Autopilot System. We
recommend that you do not lengthen this
cable.
However, if you must extend the cable:
•Use the shortest extension length
possible; it must be less than 10 feet
(3 m) in length.
•Use no less than #10 or 12 AWG
conductors. Splice and solder the
joints.
•Make the joints watertight by using
heat-shrink tubing and silicon, or
some other watertight covering.
Power Cable
The Power Cable is labelled with a "5".
Connect the Power Cable to a breaker
capable of supplying at least 20 Amperes
at 12 Volts DC.
The white wire is for Battery Positive from
the breaker. The black wire is Battery
Negative. The green wire must be wired
to the ground point (see below).
Route Cable #5 to the Processor location.
Keep the breaker turned off until you
have connected the wires to the breaker.
Grounding
The Power Cable also contains a
grounding wire. Connecting this wire to a
good ground (see * below) may reduce
static on radios and improve GPS
reception.
Many different grounding methods can be
used:
1. If you have a small vessel, the
negative battery post can be used.
•If you have several electronic
instruments, each must be
attached to the battery individually.
Do not connect one instrument to
another and then to the battery
post.
2. If you have a ground plane for a radio
on your boat, connect the ground wire
to that ground plane.
* A proper ground connection point must
be at the same voltage level as battery
negative. Any difference in voltage
between battery negative & the ground
point may indicate a problem in the
wiring, and so the ground-point wiring
must be re-done, or replaced. Ensure
that all ground connection wires are as
short as possible, and that all connectors
are clean.
Document PN 29010014 V2.3 14

ComNav Marine 1440 & 1460 Autopilot Systems
1440 Receptacle &
Control Head
Installation
The receptacle is attached
to the Control Head’s end
of Cable #1. The diagram
to the right shows the
receptacle mounted in a
panel.
Mount the receptacle near
your normal steering
position. The curly cord
on the Control Head lets
you move about 5 feet
away from the Receptacle.
A stainless steel ring is
placed between the bolt
heads and the receptacle
flange. Do not attempt to
seal the receptacle by
over-tightening the bolts, since the ring will deform the receptacle and interfere with plug
insertion. A proper caulking compound or sealant should be used instead. The three bolts
should only be tightened enough to compress the lock-washers, no more. The plug has a
tight-fitting seal, and insertion into the receptacle may be stiff, so a lubricant has been
included in the Accessory Kit.
Cable 1 Receptacle Installation
•The receptacle body requires a 0.825” (21 mm) clearance hole.
•Flange holes are for a #6 (3 mm) fasteners. Put the receptacle in its hole, and use
the holes in its lip to mark the holes for the flange.
•You must supply the flange fasteners; their length depends on the thickness of the
mounting panel. Corrosion-resistant fasteners are recommended; if metal, they
should be stainless steel, to be compatible with the flange.
Mounting Clip Installation
The Clip is used for mounting the Control Head. The Clip is mounted with two #10 (5 mm)
screws or bolts (supplied by you – use a corrosion-resistant type, and a style & length
suitable to the mounting surface).
The usual mounting location is on the dashboard, within easy reach when you are steering
your vessel.
Document PN 29010014 V2.3 15

ComNav Marine 1440 & 1460 Autopilot Systems
Document PN 29010014 V2.3 16
1460 Control Head installation
The 1460 Control Head can either be surface-mounted on a suitable flat-surface panel at
the main steering station (for example, on the dashboard), or flush-mounted in an opening
in the panel. The panel must be less than about ½” (15 mm) thick.
Thread the studs (M5 x 30 mm SS) supplied in the 1460 Accessory Kit into the nut inserts
on the back of the Head; use some thread-lock to secure them.
1. Surface mount:
•Drill 3 holes in the panel, using the flush-mount bracket as a template for the
location & size of the holes; the centre hole (9/16”, 14 mm) is for the cable, the
outer two holes (15/64”, 6 mm) are for the fasteners.
•Route Cable #1 from the Head through the large centre hole you drilled in the
panel, and then on to the Processor.
•Fasten the Head to the panel, from the rear, using the supplied nuts & washers.
2. Flush mount:
•Carefully cut out an opening the panel, slightly bigger than the back part of the
Head but smaller than the outer rim of the Head’s face (see the drawing below
for dimensions); the cut-out must have straight edges & radiused corners.
•Route Cable #1 from the Head through the opening, the large hole in the centre
of the flush-mount bracket, and then on to the Processor.
•Fasten the Head to the panel, from the rear, using the bracket and the supplied
nuts & washers; the bracket’s ears must press against the back of the panel.
•You should use a suitable sealant when flush mounting the Head. Apply a small
bead of the sealant in the groove on the underside of the Head’s front lip, or on
the edge of the cut-out in the panel.
⇒Be careful to not cover the small square hole in the middle of the bottom
edge of the Head. This hole must vent to atmosphere!
Cut-Out & Radius Dimensions for the 1460 Control Head (NOT TO SCALE)