ComNav 1500 User manual

Marine Ltd.
1500 Autopilot – Stand Alone System
1510 Autopilot – Network System
Operation & Installation Instructions
Version 2.0
ComNav R

ComNav 1500 / 1510 Autopilot
Welcome
Congratulations on your purchase of ComNav Marine’s NX2 1500 Autopilot System! At ComNav, we
are proud of our prominence as a leader in the design and manufacture of marine Autopilot systems.
Our dedication to performance and reliability will ensure your satisfaction with the ComNav 1500.
Developed as a result of ComNav’s many years of experience in Autopilot design, the 1500 system
provides excellent performance and more features than any other Autopilot in its class.
Yours truly,

ComNav 1500 / 1510 Autopilot
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 Section 12 of this manual.
Operator’s Warning
The 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 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.

ComNav 1500 / 1510 Autopilot
About This Manual
This manual provides essential information for the safe and
reliable operation of the 1501 Autopilot System. You are urged to
read this manual in its entirely before you use your Autopilot for
the first time, and to keep it handy until you become thoroughly
familiar with the operation of your Autopilot.
Throughout this manual, you will see a number of different
typefaces used, as well as some distinct phases, or “jargon”.
Please take a moment to become familiar with the following terms:
•Each time a push-button is referred to in this manual, the push-button name will
appear in bold and CAPITAL letters, e.g. MODE.
•Unless otherwise stated, the push-button presses are momentary.
•Each time a function is mentioned in the text, it will be in brackets and in the
same format, where possible, as displayed, e.g. [HDG] for HeaDinG.
•With the word navigator we mean a GPS, Loran or Decca instrument.
•Which instrument is navigating? By the term navigating, we mean the active
instrument in which the waypoint memory is used for navigation to calculate the
navigation data, i.e. BTW, DTW etc. There can only be one instrument on the
NX2 Network which is keeping the waypoints in memory, but the waypoints can
be reached from all instruments.

ComNav 1500 / 1510 Autopilot
1. INTRODUCING THE COMNAV NX2 1500 AUTOPILOT .......................................... 1
1.1 Capabilities............................................................................................................. 1
1.2 Principle of Operation............................................................................................. 2
1.3 Components........................................................................................................... 3
1.3.1 Autopilot Instrument Control Head...................................................................... 3
1.3.2 45 ° Flux Gate Compass..................................................................................... 3
1.3.3 35 ° Flux Gate Compass..................................................................................... 3
1.3.4 Distribution Unit .................................................................................................. 3
1.3.5 Rudder Follower & Linkage ............................................................................... 3
1.3.6 Reversing Pumpsets........................................................................................... 4
1.3.7 Linear Drive ........................................................................................................ 4
1.3.8 Solenoid Valve Drive .......................................................................................... 4
1.4 Accessories............................................................................................................ 5
1.4.1 NX2 Autopilot Instrument Control Head.............................................................. 5
1.4.2 NX2 Remote Control Instrument......................................................................... 5
1.4.3 NX2 Analog Rudder Angle Indicator Instrument (RAI) ....................................... 5
1.4.4 NX2 Multi Control Instrument with Server........................................................... 5
1.4.5 External Alarm Buzzer ........................................................................................ 5
1.4.6 NFU Jog Lever.................................................................................................... 5
2. INSTALLATION ......................................................................................................... 6
2.1 General Comments ................................................................................................ 6
2.2 Distribution Unit 1500 & 1510................................................................................. 7
2.2.1 Distribution Unit Connections ........................................................................... 10
2.2.2 Safety Switch .................................................................................................... 10
2.2.3 DIP Switches .................................................................................................... 10
2.2.4 Trim Potentiometers ......................................................................................... 10
2.3 Control Head ........................................................................................................ 11
2.4 Flux Gate Compass.............................................................................................. 13
2.5 Rudder Follower & Linkage ................................................................................. 15
2.6 Analog Display Rudder Angle Indicator................................................................ 16
2.7 NMEA 0183 Compass Interface........................................................................... 17
2.8 LFU101 Full Follow Up (FFU) Tiller Steering ....................................................... 17
2.9 Reversing Pumpsets ............................................................................................ 17
2.10 Installing Fittings................................................................................................ 20
2.11 Mounting the Pumpset...................................................................................... 20
2.12 Piping the System............................................................................................. 21
2.13 Filling the System ............................................................................................. 21
2.14 Linear Drive ...................................................................................................... 21
2.15 Solenoid Valve Controlled Pumpsets ............................................................... 23
2.16 Accessories ...................................................................................................... 23
3. ADVANCED OPERATION....................................................................................... 24
3.1 Adjusting Response (See Calibration Menus)...................................................... 24
3.2 Rudder [RUD] Function ........................................................................................ 24
3.3 Sea State [SEA] Function..................................................................................... 24
3.4 Counter Rudder [CRD] Function .......................................................................... 24
3.5 Automatic Trim [ATC] Function ............................................................................ 25
4. AUTOPILOT INSTRUMENT CONTROL HEAD OPERATION ................................ 26
4.1 Instrument Overview ............................................................................................ 26
4.1.1 Instrument Display............................................................................................. 26
4.1.2 Instrument Pages and Functions...................................................................... 26

ComNav 1500 / 1510 Autopilot
4.1.3 Instrument Modes ............................................................................................. 26
4.1.4 Power On/Off .................................................................................................... 26
4.2 How to Use the Push-Buttons .............................................................................. 27
4.2.1 MODE................................................................................................................ 27
4.2.2 LEFT.................................................................................................................. 27
4.2.3 RIGHT ............................................................................................................... 27
4.2.4 SET.................................................................................................................... 27
4.2.5 OFF ................................................................................................................... 27
4.2.6 Tack................................................................................................................... 27
4.2.7 Setup Mode ...................................................................................................... 28
4.2.8 Lighting ............................................................................................................. 28
5. FUNCTION .............................................................................................................. 29
5.1 Standby Mode ...................................................................................................... 29
5.2 Autopilot Mode ..................................................................................................... 29
5.2.1 Activate Automatic Steering ............................................................................ 29
5.2.2 Turn Off Automatic Steering ............................................................................ 29
5.2.3 Automatic Steering by Compass ..................................................................... 30
5.2.4 Automatic Steering by Navigator ...................................................................... 30
5.2.5 Automatic Steering by Wind ............................................................................. 31
5.2.6 Power Steering................................................................................................. 32
5.2.7 Dodging and Returning to last Automatic Steering Function............................ 32
6. SETUP..................................................................................................................... 33
6.1 Setup Mode.......................................................................................................... 33
6.1.1 Setup Mode Divided into 4 Setup Groups ........................................................ 33
6.1.2 Access Setup Mode.......................................................................................... 33
6.1.3 Change a Setting.............................................................................................. 33
6.1.4 Return to Previous Mode .................................................................................. 33
6.1.5 Factory Default Settings ................................................................................... 33
6.2 Lighting Setup Group [Lit]..................................................................................... 34
6.3 Autopilot Setup Group [P]..................................................................................... 34
6.3.1 P0, Return [RET] .............................................................................................. 34
6.3.2 P1, Rudder [RUD]............................................................................................. 34
6.3.3 P2, Damping of compass heading [SEA].......................................................... 35
6.3.4 P3, Counter Rudder [CRD]................................................................................ 35
6.3.5 P4, Damping of wind [WSE] .............................................................................. 36
6.3.6 P5 Automatic Trim Calibration [ATC]................................................................. 36
6.3.7 P6, Adaptive Control [ADC] ............................................................................... 36
6.3.8 P7, Automatic Pilot Calibration [APC]............................................................... 36
6.3.9 P8, Rudder Reduction Speed [RRS] ................................................................ 37
6.3.10 P9, Rudder angle limit [LIM].......................................................................... 37
6.4 Alarm Setup Group [A] ......................................................................................... 38
6.4.1 A0, Return [RET] .............................................................................................. 38
6.4.2 A1, Pilot Course Alarm [PCA]........................................................................... 38
6.4.3 A2, Timer Watch Alarm [TMR].......................................................................... 38
6.4.4 A3, Cross Track Error Alarm [XTA] ................................................................... 38
6.4.5 A4, Push-Button Beep [KEY]............................................................................. 38
6.5 Compass Setup Group [C] ................................................................................... 39
6.5.1 C0, Return [RET] .............................................................................................. 39
6.5.2 C1, Magnetic Heading [MAG] ........................................................................... 39
6.5.3 C2, Local Magnetic Variation [VAR] ................................................................. 39
6.5.4 C3, Auto-Deviation [Auto DEV]......................................................................... 39

ComNav 1500 / 1510 Autopilot
6.5.5 C4, Check Auto-Deviation [Auto CHK] ............................................................. 40
6.5.6 C5, Clear Auto-Deviation [Auto CLR] ................................................................ 40
6.5.7 C6, Adjust Compass Alignment [ADJ] .............................................................. 41
7. DOCKSIDE TESTING.............................................................................................. 42
7.1 Preparations......................................................................................................... 42
7.2 Dockside First Start Up ........................................................................................ 42
7.2.1 Power On........................................................................................................... 42
7.2.2 Initializing the Instrument in a NX2 Network...................................................... 42
7.2.3 Re-Initializing the Instrument ............................................................................ 43
7.3 Remove Air from System ..................................................................................... 43
7.4 Adjust the Pumpset Flow Rate ............................................................................. 44
7.5 Functional Tests................................................................................................... 44
8. SEA TRIALS ............................................................................................................ 45
8.1 Preparations......................................................................................................... 45
8.2 Compass Calibration............................................................................................ 45
8.3 Automatic Pilot Calibration [APC]......................................................................... 45
9. FINE TUNING .......................................................................................................... 47
9.1 Optional Fine Tuning for Special Applications...................................................... 49
10. PROBLEM SOLVING........................................................................................... 50
10.1 General............................................................................................................. 50
10.2 Symptom - Cause - Action................................................................................ 50
10.3 NX2 Network Error Messages with Cause and Remedy .................................. 53
11. MAINTENANCE ................................................................................................... 55
11.1 Instrument Maintenance ................................................................................... 55
11.2 Drive Unit Maintenance and Inspection Schedule ............................................ 55
12. TECHNICAL SPECIFICATIONS.......................................................................... 56
12.1 Autopilot Instrument.......................................................................................... 56
12.2 Distribution Unit A-1500.................................................................................... 56
12.3 Distribution Unit A-1510.................................................................................... 56
12.4 Rudder Follower & Linkage .............................................................................. 56
12.5 Pumpsets.......................................................................................................... 57
12.6 Linear Drive ...................................................................................................... 57
12.7 Solenoid Valve Drive ........................................................................................ 57
12.8 NX2 Network Specification ............................................................................... 57
13. Abbreviations........................................................................................................ 58

ComNav 1500 / 1510 Autopilot - 1 -
1. INTRODUCING THE COMNAV NX2 1500 AUTOPILOT
1.1 Capabilities
The ComNav NX2 1500 and 1510 Autopilots are designed for power and sailing
vessels from 26ft (8m) to over 160ft (50m) length. Design and manufacturing
techniques developed over many years have resulted in a versatile and heavy-duty
unit. Hydraulic drive units of the reversible motor variable speed (PWM) type provide
precise control while consuming low battery power. Connection can be made to
solenoid valves of electro-hydraulic steering systems, allowing use on very large
vessels. Hydraulic linear drives provide powerful and accurate control when
connected to mechanical steering systems and provide an independent hydraulic
steering for added safety.
No Autopilot can steer better than its compass stability will allow and the flux gate
compass excels in this characteristic. Silicone oil dampening of the flux gate
prevents compass instability even for high speed vessels slamming in heavy seas.
This combined with the high gimbal angle of +/- 45°, eliminates compass
disturbance with vessel heeling or rolling. A sensitive automatic gain design
provides improved compass operation especially in high latitudes and automotive
deviation compensation ensures accurate indication. As an alternative an NMEA
0183 output flux gate compass can be connected to this Autopilot for greater
interfacing flexibility. An optional fluid compass sensor may be used and slaved to
the vessel’s main magnetic compass if it is of the externally gimballed type. This is
particularly important on steel-hulled vessels. For larger vessels a gyro-compass
may be interfaced for even greater steering accuracy.
Power steering, either through the Control Head push buttons or an operational jog
steering level may be used to avoid heavy wheel effort when maneuvering.
Alarms for off course, off track or watch alarm and other faults are included with
provision for an optional loud remote alarm. Interface to radio navigational receivers
including GPS, Loran, Satnav, Decca and Plotters allows precise waypoint arrival
and multiple waypoint sequencing. Unique adaptive controls provide very powerful
and smooth steering control which automatically adjusts to changing operational
conditions.
A large number of Autopilot stations may be connected. Control techniques
developed over many years allow very stable course holding with minimum
corrections. Weather helm is automatically compensated for by an automatic trim
and counter rudder that provides enhanced response in quartering seas under large
course changes. Some Autopilot features described above may not be available
with the 1510 system.

ComNav 1500 / 1510 Autopilot - 2 -
1.2 Principle of Operation
The powerful microprocessor in the Distribution Unit accepts heading information
from magnetic or gyro compasses and radio navigation receivers and compares this
against the course set by the Control Head and rudder information as sent by the
Rudder Transmitter. Any difference between the set and actual course is compared
along with the rate of change and trends in change (PID control), to drive the
Pumpset motor or solenoid directional valve, moving the rudder as necessary to
return the vessel back to course. The sensitivity to course errors and amount of
correction are user adjustable to suit different vessels under changing sea
conditions. Factory default settings establish a basis for normal steering and may be
further optimized as necessary. During set up procedures, the compass is
automatically compensated and installation errors such as reversed rudder feedback
and reversed Pumpset wiring or piping are automatically diagnosed and corrected.
During this procedure the rudder speed is automatically optimized. This greatly
reduces installation calibration and sea trials time while eliminating possible
Autopilot malfunction.

ComNav 1500 / 1510 Autopilot - 3 -
1.3 Components
1.3.1 Autopilot Instrument Control Head
The control and display of all Autopilot functions are provided
by the Control Head. It is waterproof and may be mounted
below or above deck. Multiple Control Heads are connected
in parallel (daisy chain) and any station may be activated by
pressing any one of its keys. A portable Control Head is also
available for remote control (not shown).
PN 20620044
1.3.2 45 ° Flux Gate Compass
The flux gate compass provides a stable heading reference
for the Autopilot and course repeater function on the Control
Head. It is gimbaled to accept up to +/- 45 ° of pitch and roll
and should be bulkhead mounted below decks near the
center of pitch and roll for maximum stability. Construction is
splashproof. The Autopilot may also be used to transmit
NMEA heading data to additional receivers such as radars,
plotters, compass repeaters etc.
PN 20640006
1.3.3 35 ° Flux Gate Compass
The flux gate compass is low weight, fluid damped and
compact in size allowing for mounting in cramped areas. It
can be flush mounted and is auto-deviated from the Autopilot
Instrument Control Head.
PN 20640007
1.3.4 Distribution Unit
The Distribution Unit contains the course computer and motor
drive circuitry and acts as a central distribution for
interconnecting wiring. This unit accepts data from the
compass, Control Heads, radio navigational receivers and
Rudder Transmitter. The DU-1500 is waterproof and may be
mounted in any convenient and cool area. The DU-1510 is
splashproof and should be mounted in a water protected cool
area. (shown) DU-1500 PN 20090002
DU-1510 PN 20100002
1.3.5 Rudder Follower & Linkage
The Rudder Follower & Linkage provides the Autopilot with
accurate rudder position information. It is mounted near the
rudder shaft and connected to the tiller or quadrant with a ball
joint linkage. PN 20330008+20330007
OFF
N2
AUTOPILOT
SET
MODE