ComNav 1440 User manual

P/N 83468 V1.2
INSTALLATION and OPERATION MANUAL
COMNAV 1440/1460 AUTOPILOTS
COMNAV 1460 AUTOPILOT
COMNAV 1440 AUTOPILOT
COMPLIES WITH
CE REGULATIONS

P/N 83468 V1.2 2
ComNav Marine Autopilots
#15 - 13511 Crestwood Place
Richmond, BC
Canada V6V 2G1
Phone: [phone]
Fax: [phone]
In Canada or the USA
Toll Free Phone: [phone]
Toll Free Fax: [phone]
E-Mail: [email protected]
Web Site: www.comnavmarine.com
Owner's Manual for Installation and Operation of 1440/1460 Autopilot
Part Number: 83468
First Printing: May 1999
Revised: June 2000
COMPLIES WITH
CE REGULATIONS

P/N 83468 V1.2 3
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 on the
following pages.
OPERATORS WARNING
This Autopilot will automatically steer your vessel 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. This
system does not reduce your responsibility for the control of the vessel when
under way. 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 under way, your vessel must be under the control of a qualified and
alert person.

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June 15, 2000
This document, ComNav Part No. 83468, V1.2, is the approved Installation and User's Manual for use
with the ComNav 1440/1460 Autopilot. Where versions of this manual exist in other languages, the
English version shall be considered authoritative. Suggestions for changes or improvements may be
directed to the Sales Manager at ComNav Marine Ltd.
Richard Summers
General Manager
ComNav Marine Ltd.

P/N 83468 V1.2 5
TABLE OF CONTENTS
PRODUCT DESCRIPTION..................................................................................................................................................7
BEFORE YOU START ..........................................................................................................................................................8
Unpacking and Identification................................................................................................................................................8
Manual Conventions..............................................................................................................................................................8
Complete Tool List................................................................................................................................................................8
1440/1460 System layout....................................................................................................................................................10
1440/1460 PARTS LIST........................................................................................................................................................11
INSTALLATION INSTRUCTIONS..................................................................................................................................15
ComNav Marine Reversing Pump......................................................................................................................................15
Tools and Materials Required To Install Pump..................................................................................................................16
Hydraulic Connections For Two-Line Steering Systems ..................................................................................................19
Hydraulic Connections For Three-Line Steering Systems ................................................................................................20
Technical Specifications......................................................................................................................................................21
Specifications Common To Both Pumps............................................................................................................................21
Planning ...............................................................................................................................................................................23
Tools.....................................................................................................................................................................................24
Clip Installation....................................................................................................................................................................25
Fluxgate Compass Installation............................................................................................................................................26
Rotary Rudder Feedback Installation..................................................................................................................................27
Attaching the Rudder Feedback Linkage ...........................................................................................................................29
Outboard Feedback Installation..........................................................................................................................................33
Wiring the Processor ...........................................................................................................................................................37
PILOTING WITH THE 1440 OR 1460 AUTOPILOT ...................................................................................................61
Setting Slow Speed Rudder Response................................................................................................................................62
Turns and Changing Course................................................................................................................................................63
Setting Fast Speed Rudder & Counter-Rudder Response .................................................................................................65
Fast Speed Turns and Course Changes...............................................................................................................................66
Adjusting Your Digital Rudder Angle Indicator (RAI).....................................................................................................68
Using Your Navigation Interface........................................................................................................................................69
The Navigation Interface.....................................................................................................................................................70
NMEA 0183 ........................................................................................................................................................................70
ADJUSTMENT COMMANDS ...........................................................................................................................................75
USER CODES FOR THE 1440 & 1460..............................................................................................................................76
PROBLEMS WITHOUT AN ERROR CODE.................................................................................................................79
APPENDIX A.........................................................................................................................................................................80
Connections to 4 and 5 Wire Motors..................................................................................................................................80
APPENDIX B .........................................................................................................................................................................82
Connections to Solenoid Valves.........................................................................................................................................82
APPENDIX C.........................................................................................................................................................................83
Connecting a Second Location or Second Station Options...............................................................................................83
Second Location Kit............................................................................................................................................................83
Second Station Kit...............................................................................................................................................................84

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APPENDIX D.........................................................................................................................................................................86
Connecting a Rudder Angle Indicator................................................................................................................................86
APPENDIX E .........................................................................................................................................................................87
Connecting the NMEA 0183 Heading Output...................................................................................................................87
LIMITED WARRANTY AGREEMENT..........................................................................................................................89
CE COMPLIANCE...............................................................................................................................................................92

P/N 83468 V1.2 7
PRODUCT DESCRIPTION
ComNav 1440 or 1460 Autopilots are reliable,
accurate and easy to use aids to navigation.
They feature four operating modes, watertight
design, and built-in navigation interface.
The 4 operating modes are:
•STANDBY MODE allows manual steering
while displaying compass information.
•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 or 1460 is connected to an
appropriate navigation device.
In both PILOT and NAV Mode, pressing the
Red or Green Key allows use of the
Dodge/Course-change feature.
To steer a constant heading, the 1440 or 1460
compares compass heading information with
the course heading that is entered into
memory. If the vessel is not on the correct
heading, the Autopilot calculates the rudder
position that will bring the vessel onto the
correct heading. The Autopilot uses a drive unit
to move the rudder. 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.
When steering along a course line, both
Autopilots use information from the compass to
monitor the heading. They also use position
information received in NMEA 0183 format
from LORAN, GPS, or plotter. Using both of
these inputs, the 1440/1460 calculates a
course to steer and keeps the vessel on the
course line.
The 1440/1460 contains a program called
Ghost Rudder. Should the Rudder Feedback
fail, the Autopilot will use its memory of the
rudder movement to calculate new rudder
positions. The Ghost Rudder program 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 to the
Rudder Feedback.
The design of the 1440/1460 includes many
circuit protection devices such as; reverse
power connection protection, output circuitry
overload protection, protection against
overheating, protection against computer
failure or program error.
SPECIFICATIONS
Voltage: 10VDC - 40 VDC
Steering Outputs: 20 Amperes Maximum
Sizes L X W X H
1440 Control: 2.75 x 5.13 x 1.0 in.
(7.0 x 13.3 x 2.5 cm.)
1460 Control: 6.0 x 3.1 x 1.0 in
(15.4 x 7.9 x 2.5 cm)
Processor: 6.3 X 15 X 2.7 in.
(16.0 x 38.1 x 6.9 cm.)
Compass: 5.6 x 4.2 x 3.4 in.
(14.2 x 10.7 x 7.6 cm)
Pump: 4.8 x 7.5 x 4 in.
(12.2 x 19.0 x 10.2 cm.)

P/N 83468 V1.2 8
BEFORE YOU START
Unpacking and Identification
Please make sure that you have found and
identified all of the components of your 1440
or 1460 Autopilot before you begin
installation. Use this manual, which begins
with a parts list, to identify the components.
Your Autopilot will have a Rotary Rudder
Feedback or an Outboard Motor Feedback.
The manual contains separate sections about
both Feedback units.
Manual Conventions
In this manual, the names of the components
are always capitalized. For example,
"Processor".
Also, the keys on the Controller face are
capitalized. For example: Set Key.
When you are required to perform an action
with the key, it is underlined. For example,
"Press the Red Key."
Your ComNav 1440/1460 Autopilot has 4
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 Unit the
text will show the display in this way:
[r’tSt]
The square brackets represent the frame of
the display. Lower case and upper case
letters will often be mixed together in the
display. The letters inside the square
brackets will be mixed in the same way as the
display. Often a drawing of the display will
follow the text.
When a particular display is first mentioned in
a section, the message represented by the
display will follow. For example: [r’tSt]
(rudder test), [HO S] (hard over to starboard).
Complete Tool List
A list of tools you will require for the
installation of the Reversing Pump is on page
16.
A list of tools you need to install the
Autopilot's electrical components is on page
24.
A list of tools you need to install the 1440 or
1460 Autopilot and the Reversing Pump
begins here:
1) Basic Tool Kit
2) Pipe Cutter
3) Funnel with Filter (a coffee filter will
do)

P/N 83468 V1.2 9
4) 3/8" Electrical Drill
5) Bucket large enough to catch oil that
will drain from the hydraulic steering
system when it is opened.
6) Rags or Paper Towels
7) Pipe Fittings (check with steering
gear manufacturer for type and
size)1
8) Tubing (check with steering gear
manufacturer for type and size)1
9) Hydraulic Oil (check with steering
gear manufacturer for type)1
1Consult with your steering system manufacturer
to get detailed information about factory
authorized materials. Failure to do so could void
your warranty.
10) Teflon based thread sealer (such as
LOCTITETM P.S.T.)
11) Miscellaneous Hardware (for
mounting pump and securing lines)
12) Screwdriver: One Phillips, one slot
screwdriver
13) Wire Cutters: A pair of ordinary wire
cutters suitable for general work
around your house.
14) Drill and a selection of Drill Bits.
15) Small Adjustable Wrench
If you purchased a 1440/1460 with a Rotary
Rudder Feedback you may need one
stainless steel band clamp which is more
than large enough to fit around your rudder
post.
You may also wish to have a supply of tie
wraps for securing cables, and tools specific
to your boat.

P/N 83468 V1.2 10
1440/1460 System layout

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1440/1460 PARTS LIST
Parts are not drawn to any scale.
Processor: Part Number 82614.
FOR 1440 AUTOPILOT PACKAGES
1440 Control Unit. Part Number 82600. This part includes a curly
cord wired to the Control Unit.
1440 Control Unit Clip and Spacer. Part
Number 65127.
FOR 1460 AUTOPILOT PACKAGES
1460 Control Unit and Mounting Bracket. Part Number 83454.
This part includes a 25 foot (7.7 meter) cable wired to the Control
Unit.

P/N 83468 V1.2 12
1440/1460 Fluxgate Compass. Part Number
92156. This part includes 40 feet (12.2 m) of
cable wired to the compass.
In this group, one part OR the other part will be included:
Rotary Rudder Feedback: Part Number 81868. This part includes 50 feet (15.2 m) of cable wired to
the Rudder Feedback. This part will always come with:
Rotary Rudder Feedback Linkage Kit.
Part Number 81854
OR
Outboard Feedback: Part Number 81957. This part includes
30 feet (9.1 m) of cable wired to the Rudder Feedback.
P/N 51570
P/N 51776
P/N 51730

P/N 83468 V1.2 13
Also included but not drawn:
•Power Cable: Seven and a half feet (2.3 m) of cable provided for connection of Processor and
breaker.
•Accessory Kit: Contains extra terminal sockets and gland.
•Control Unit Interconnection Cable (1440 systems only): 10 feet (3.05 m) of cable with a
receptacle and cap on one end. Labelled as cable one.
•ComNav 1440 and 1460 Autopilot Manual. Part Number 83468.
Adjustable Reversing Pump. Part Number 82333 (12VDC/18CI),
82632 (24VDC/18CI), 82767 (12V/30CI) and 82771 (24V/30CI). 18CI
pumps are for installations where the steering ram size is from 7 in3
(115 cm3) up to 18 in3(295 cm3). 30CI pumps are for installations
where the steering ram size is from 15 in3(245cm3) up to 30 in3(490
cm3).

P/N 83468 V1.2 14
This page is intentionally blank.

P/N 83468 V1.2 15
INSTALLATION INSTRUCTIONS
COMNAV MARINE REVERSING PUMP
Part Nos. 82333, 82632, 82767 & 82771
GENERAL:
The reversing pump consists of a hydraulic pump and a motor. The pump is a piston type, driven
by a reversing permanent magnet motor. The pump is designed in such a way that it will keep oil
from returning through the pump when is not running or correcting. There is also a bleed-to tank to
allow the use of unbalanced cylinders. The pump is compatible with all hydraulic steering systems
including pressurized steering systems such as Hynautic.
To adjust flow rate, loosen pump housing screws and turn pump housing. Clockwise will decrease
flow rate, anti-clockwise to increase flow rate.
Part Nos. 82333(12V) & 82632(24V) 18CI Pumps
The pumps above can be ordered with a 12VDC, or 24VDC motor and have an adjustable flow rate that will
deliver from 36 in3to 73 in3(600 cm3– 1200 cm3) per minute of oil at 500 PSI (3,440 kPa) (34 Bar). It is
suitable for rams with displacements ranging from 7 in3(115 cm3) to 18 in3(295 cm3)) displacement.
Part No. 82767(12V) and 82771(24V) 30CI Pumps
The pumps above can be ordered with a 12VDC or 24VDC motor and have an adjustable flow rate that will
deliver from 61 in3to 122 in3(1000 cm3– 2000 cm3) per minute of oil at 500 PSI (3,440 kPa) (34 Bar). It is
suitable for rams with displacements ranging from 15 in3(246 cm3) to 30 in3(495 cm3) displacement.
SPILL VALV
E
ADJUSTMENT

P/N 83468 V1.2 16
***** IMPORTANT *****
If the system you purchased includes a reversing motor pumpset, it is important that you apply and
install this unit correctly. To ensure that you get the most from your purchase, read this installation
and instruction manual carefully. By following the step-by-step procedure and using only basic
tools and materials, you will find the installation easy to do.
Caution
This Pump is not waterproof and is therefore not warranted against water damage.
This Pump is not warranted against damage caused by improper installation.
If you are installing this pump on a Capilano or Syten steering system, you probably have a
3-line steering system. Read the 3-line steering installation instructions carefully.
Tools and Materials Required To Install Pump
1) Basic Tool Kit
2) Pipe Cutter
3) Funnel with Filter (a coffee filter will do)
4) 3/8" Electrical Drill
5) 2 gallon (9 L.) bucket (to catch excess
oil).
6) Rags or Paper Towels
7) Pipe Fittings (check with steering
gear manufacturer for type & size)1
8) Tubing (check with steering gear
manufacturer for type and size)1
9) Hydraulic Oil (check with steering
gear manufacturer for type)1
10) Teflon based thread sealer (such as
LOCTITE™ P.S.T.)
11) Miscellaneous Hardware (for
mounting pump and securing lines)
1. Consult with your steering system manufacturer to get detailed information
about factory authorized materials. Failure to do so could void your
warranty.

P/N 83468 V1.2 17
Planning
Installation of the pump consists of:
•Finding a mounting location for the
pump
•Partially draining the steering system
•Mounting and connecting the pump to
the existing steering lines
•Filling and bleeding the steering
system.
A suitable mounting location for the pump
MUST:
•Be dry
•Be lower than at least one of the helm
pumps in the steering system
•Provide a solid mounting base
•Be at least 4 feet (3.1 m) from the
vessel’s compass.
A mounting location for the pump SHOULD:
•Provide easy access to the pump
•Provide an easy connection point to
the steering system
•Minimize the length of the pump hoses
•Minimize the length of the wires to the
motor.
A typical mounting location would be in the
engine compartment or the steering console.
The pump can be mounted in any orientation
except with Port C facing downward. If Port
C is facing downward then air will not be able
to rise out of the pump and the pump will not
have a supply of oil.
There are two ways to connect the pump to
the steering system. The first is to leave the
system completely filled and be careful not to
spill hydraulic fluid. The second is to drain
the system of fluid completely before cutting
or opening any lines.
If you follow the first method, remember that
when you disconnect or cut the steering
lines, there will be a constant slow discharge
of oil due to gravity draining the system.
Have a container ready to catch all excess
oil. Do not reuse any oil reclaimed from your
system.
Draining your System
If you wish to follow the second method and
drain the system, use the following simple
procedure.
1. Have a large container, about 2 gallons,
ready.
2. Disconnect the delivery lines at a low
point, usually where the lines connect to
the steering cylinder.
3. Turn the wheel of the highest helm pump
in both directions until no more fluid
comes out of the lines.
4. Repeat the previous step on each lower
helm pump in turn.
Types of Steering Systems
There are two general types of steering
systems, two-line systems, and three-line
systems. The pump connection to the
steering system is different for each type.
Separate instructions are supplied for both
types of steering systems.

P/N 83468 V1.2 18
You have a three-line system if the helm pump is a Capilano Model 250 or 275 (Made by Teleflex),
or if there is a Uniflow valve mounted close to the steering cylinder.
You have a two-line system if you do not have the above components in your system.
CAUTION
CLEANLINESS must be maintained while making hydraulic connections. Contamination
introduced into the steering system fluid can cause steering components to malfunction, possibly
resulting in a loss of steering.
Before beginning to connect the pump to the steering system, review the following installation
hints:
•Cap or cover the ends of hoses with a
clean rag before pushing them between
bulkheads.
•Wipe copper filings off freshly cut and
reamed copper tube. Do not blow the
filings off.
•Teflon based thread sealer, such as
'LOCTITE™ P.S.T.' must be used on all
male pipe threads. Do not place thread
sealer on the first two threads. Do not
use a tape-type thread sealer. These can
shred and enter the steering system fluid.
Do not place thread sealer on female pipe
threads.
•When tightening fittings into the pump
lockvalve, hold the lockvalve, not the
motor. That way, the lockvalve will not
twist out of alignment with the rest of the
pump.
•Connection of the pump lines is most
easily made at existing breaks in the
steering system lines. For example:
valves, t-joints and other fittings.
CAUTION
Opening your hydraulic steering system will introduce air into your steering system. This air will be
expelled if the steering system is bled properly. After you refill your system and during the "Set-up
Routine", your autopilot can be used for bleeding the air. Ensure that you follow the Compensating
Line installation instructions very carefully as all air is expelled through this line when bleeding your
system. If the Compensating Line does not prime properly and allow fluid to get to the autopilot
pump, the pump will not perform properly. The Compensating Line does not have to be a high-
pressure hose. In fact, even a clear hose can be used allowing for easy visual confirmation of
proper Compensating Line operation.

P/N 83468 V1.2 19
Hydraulic Connections For Two-Line Steering Systems
A simple schematic of the pump installation is shown below.
2 Line Steering System Installation
Delivery Lines:
Ports A and B in the diagram above are the input/output ports of the pump and must be
connected to the steering lines coming from the steering cylinder. It does not matter which pump
port is connected to which steering line.
Compensating Line:
In the above diagram Port C is the compensating or bleed line, and must be connected to the
steering system's reservoir. This connection can be made at: a helm pump; remote reservoir (if
there is one); the compensating line connecting two helm pumps; or the compensating line
connecting a helm pump to the remote reservoir. If the connection is being made directly to the
helm pump, ensure that the bleed line is connected to the LOWER helm bleed port.
The compensating line MUST have a gradual rise from the pump, to the connection, to the
steering system. This allows air to rise out of the pump, ensuring a constant supply of oil to the
pump. INSTALLATION OF SHUT-OFF VALVES RECOMMENDED

P/N 83468 V1.2 20
Hydraulic Connections For Three-Line Steering Systems
A simple schematic of the pump installation is shown below.
3 Line Steering System Installation
Delivery Lines:
In the above diagram, Ports A and B are the input/output ports of the pump and must be
connected to the steering lines between the steering cylinder and the Uniflow valve. The
simplest method of doing this is to install a tee in each of the cylinder ports of the Uniflow valve
itself and connect to these tees. It does not matter which pump port is connected to which
steering line.
Compensating Line:
Port C is the compensating or bleed line and must be connected to the steering systems’
reservoir. This connection can be made at a helm pump; a remote reservoir (if there is one); the
return line connecting two helm pumps; or the return line between a pump and the Uniflow
valve. If the connection is being made directly to the helm pump, ensure that the bleed line is
connected to the LOWEST bleed port of the pump.
The connection MUST be at least six feet (1.83 m) from the Uniflow valve as shown above. If the
connection is too close to the Uniflow valve, the manual steering system may not work well.
The compensating line MUST have a gradual rise from the pump, to the connection, to the
steering system. This allows air to rise out of the pump, ensuring a constant supply of oil to the
pump. INSTALLATION OF SHUT-OFF VALVES RECOMMENDED