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.

P/N 83468 V1.2 4
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

P/N 83468 V1.2 6
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