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

ComNav 1500 / 1510 Autopilot - 4 -
1.3.6 Reversing Pumpsets
Various sizes and types of Pumpsets are available which
connect into the vessel’s hydraulic steering system,
pumping oil on command from the Distribution Unit so as
to drive the steering cylinder to the required rudder angle.
The reversing motor Pumpset is only operation when
carrying out a rudder command. When the vessel is on
course the motor stops. A variable speed motor drive
adjusts maximum rudder positioning accuracy. Optional
solenoid valve controlled Pumpsets are available for use
on larger vessels. Construction is splashproof.
1.3.7 Linear Drive
A hydraulic cylinder is provided for driving the quadrant of
mechanical steering systems. The cylinder is driven by
one of the above Pumpsets and includes a small hydraulic
reservoir and bypass valve that frees the hydraulic system
when the Autopilot is not in use. This linear drive provides
a cleaner installation (being entirely below deck) and
delivers much more torque to the rudder than wheel driven
units. In case the mechanical steering should fail, the
cylinder provides a back up hydraulic steering.
1.3.8 Solenoid Valve Drive
On larger vessels the main hydraulic steering may be fitted
with a Solenoid Valve controlled power steering. In this
case the Autopilot does not need to be supplied with a
Pumpset drive unit since the Distribution Unit output can
be reconfigured with its board mounted DIP selector switch
to provide drive for steering solenoids having coil voltages
of 12 or 24 VDC.

ComNav 1500 / 1510 Autopilot - 5 -
1.4 Accessories
1.4.1 NX2 Autopilot Instrument Control Head
Additional Autopilot Instruments Control Head (PN 20620044) may be added. They
are connected in a "daisy chain" fashion from one to the other, matching colors on
terminals. Control may be transferred from one instrument to another by simply
pressing any pushbuttons (except the OFF push-button) on the instrument where
active control is desired. All other inactive instruments will display the same
information as the active instrument, however in the lower display the text "passive"
will blink once every seven seconds.
1.4.2 NX2 Remote Control Instrument
The Remote Control Instrument (PN 20620048) is an instrument in itself that can
be set in either Autopilot mode to be used as an Autopilot instrument, or Instrument
mode displaying all information on the NX2 Network. The Network Remote Control
Instrument (PN 85006) can be used as a remote control for all instruments
connected to the Network. It is the ultimate NX2 instrument!
1.4.3 NX2 Analog Rudder Angle Indicator Instrument (RAI)
The Analog Rudder Angle Indicator Instrument (PN 20620037) indicates the rudder
angle (50°-- 0° -- 50°). This instrument is connected on the NX2 data bus cable as
per color codes.
1.4.4 NX2 Multi Control Instrument with Server
The NX2 Server is the heart of the NX2 Network to which transducers for speed,
depth, wind, compass and navigators are connected. The Multi Control is a multi-
function instrument that displays a main and a sub-function, grouped into 4 pages
for speed, depth navigation and wind information. The Multi Control instrument and
the Server are the building components of the NX2 Network.
1.4.5 External Alarm Buzzer
An external alarm buzzer (PN 30620023) can be connected to the Server only.
When activated, provides a local alarm at the Control Head in case the Autopilot
falls off course, develops a fault or the helmsman should fall asleep. The buzzer
can be positioned where it may be heard such as in the Captain's cabin, when any
alarm is activated.
1.4.6 NFU Jog Lever
A Non Follow Up (NFU) jog lever (PN 20310002) may be connected through the
Autopilot to directly control the steering Pumpset in any mode except standby
mode. This is useful for docking or remote maneuvering such as required when
picking up crab traps etc. In any automatic pilot mode, the jog steering can be used
as a dodge function and when the jog lever is let go, the boat will revert to the
previous pilot course setting.

ComNav 1500 / 1510 Autopilot - 6 -
2. INSTALLATION
2.1 General Comments
More than any other piece of marine electronics, reliable and accurate operation of
an Autopilot depends on correct installation. Please read and be sure you fully
understand the installation requirements before attempting installation.
The installation includes 6 major steps:
1. Read the installation and operation manual completely.
2. Plan where to install the equipment.
3. Run the cables.
4. Install the transducers and instruments.
3. Make the attachments needed for Pumpset and cylinder and install them.
6. Learn the functions and calibrate your system.
Before you begin drilling ... think about how you can make the installation as neat
and simple as your boat will allow. Plan where to position the transducers, Server
and instruments. Think about leaving space for additional instruments in the future.
A few ”do nots” you should consider:
• Do not cut the cables too short. Allow extra cable length at the Distribution
Box (Servo Unit) so it can be disconnected for inspection without having to
disconnect all attached cables.
•Do not place sealant behind the display. The instrument gasket eliminates
the need for sealant.
•Do not run cables in the bilge, where water can appear.
•Do not run cables close to fluorescent light sources, engine or radio
transmitting equipment to avoid electrical disturbances.
•Do not rush; take your time. A neat installation is easy to do.
The following tools and materials will be needed:
•Wire cutters and strippers.
•Small and large Philips and small flat head screw driver.
•Hole saws: 63mm OD (2½") and 89mm OD (3 ½”).
•Drill bit for 5mm OD (1/4").
•Plastic cable ties
If you are doubtful about the installation, obtain the services of an experienced
technician.

ComNav 1500 / 1510 Autopilot - 7 -
2.2 Distribution Unit 1500 & 1510
Location
The Distribution Unit must be mounted on a dry, flat and vertical surface below
deck, at least 500 mm (20") from radio receiving equipment. Since all wiring
originates at the Distribution Unit, it should be centrally located to minimize lengths
of wiring. It is most important to minimize the runs of power and motor leads since
voltage drop in these cables will reduce steering capacity.
Installation
Note: The 1500 and 1510 Autopilots are designed for different applications:
The 1500 is designed as a Stand Alone System.
The 1510 is designed to work as part of a Network System, by connecting it to the
NX2 Network.
Place the adhesive drill template provided in the desired location for the appropriate
Distribution Unit and drill accordingly. (Reference the following pages). Remove the
template. To mount the Distribution Unit, remove the cover screws. The 4 inner
mounting holes are now exposed. Mount the Distribution Unit with 4 screws (not
supplied).
Note for the 1500 Distribution Box: If any waterproof cable glands do not have
cables inserted, install the short rubber plug provided in order to maintain water
tightness. If many options are connected and not enough glands are available, use
a separate junction box and route the excess wires through one large cable in one
of the large glands.
Note for the Autopilot Instrument / NX2 Network connection. If you want to run
the NX2 Network instruments separate from the Autopilot, do not connect green
wire to (pin 1) to the left in Distribution Unit. Instead insulate the green wire.
Wire thickness - Important! Use the following table to determine wire thickness.
Total distance from battery to Distribution Unit and distance from Distribution Unit to
Pumpset must be used to determine the wire thickness from the table.
Cable Length Maximum
(m) (ft)
Wire Size
(mm2)
Wire Size
(AWG)
3102.5 14
516 4 12
7.5 25 6 10
12 40 8 8
Make sure, that the wire size between the battery and the point where you will connect
the wire to the Distribution Unit is big enough to secure power supply to all other
connected electrical units on board. If you are in doubt, ask your local technician.

ComNav 1500 / 1510 Autopilot - 8 -
PN: 29020007
0.20" DIA. , 4 OFF
FOR #8 TAPPING SCREW
5.56"
1) Make sure it is in down position for reversing pumpset application,
up for solenoid valve operation.
2) Keep in down position.
3) Keep in down position. If using analog output interface (A1100),
keep in up position.
4) Keep in down position. If using full followup (FFU) tiller steering
option, keep in up position.
5) Set as per voltage application shown above.
** Make sure power is turned off to the pilot system prior to changing
dip switches.
20
28272625242322212019181716151413121110987654321
CONTROL
HEAD
CONTROL
HEAD
CONTROL
HEAD
REMOTE
WATCH
ALARM
NMEA
OUTPUT
RUDDER FOLLOWER
& LINKAGE
BASIC SYSTEM COMPONENTS
OPTIONAL ACCESSORIES
**MAKE SURE POWER IS TURNED OFF TO THE PILOT
SYSTEM PRIOR TO CHANGING DIP SWITCHES.
VR5, VR6 - FACTORY SET - DO NOT ADJUST
RUDDER ANGLE
INDICATOR
RED
WHITE
BLACK
HYDRAULIC
PUMPSET
BATTERY
LEVER
FOLLOW-UP
JOG
STEERING
BYPASS
VALVE
NMEA
INPUT
(GPS)
FLUXGATE
COMPASS
FUSE
A-1500 SYSTEM WIRING DIAGRAM (FOR REVERSING PUMPSET)
GREEN
SHIELD
WHITE
YELLOW
GREEN
FOR COMNAV
RUDDER FOLLOWER
INSTALLATION
(SEE SECTION 2.5)
WHITE
GREEN
BLACK
VR4
VR2
(ANALOG RAI GAIN)
VR3
(ANALOG RAI OFFSET)
VR1
(ANTI-HUNT)
VR6
(CURRENT LIMIT)
VR5
(DIGITAL RAI
OFFSET)
GAIN
OFFSET
5
FUSE
MOTOR2(SOLENOID2)
5
MOTOR1(SOLENOID1)
4
COMMON
3
-BATTERY
2
+BATTERY
1
ENABLE
FFU+
FFUS
FFU-
GND
ALARM+
S2
COM
S1
-
+
GND
+
GND
DATA
GND
DATA
SHIELD
WHITE
YELLOW
24/32 VDC
12 VDC
5
DIP SWITCHES **
3421
4
3
2
1
0.2"
8.7"
4.1"
1.2"
0.8"
A-1500 DISTRIBUTION UNIT TEMPLATE
8.25"
2.2"
5.7"
5.3" UP
DOWN
DIP SWITCHES
1234
12 435
24/32 VDC
12 VDC
SHIELD

ComNav 1500 / 1510 Autopilot - 9 -
PN: 29020007
Ø0.10", 4 OFF
FOR #6 TAPPING
SCREW
2.6"
1) Make sure it is in down position for reversing
pumpset application, up for solenoid valve operation.
2) Keep in down position.
3) Set as per voltage application shown above.
Switch should be set to 12 for 12 VDC
application or set to 24 for 24 VDC application.
** Make sure power is turned off to the pilot
system prior to changing dip switches.
A-1510 SYSTEM WIRING DIAGRAM (FOR REVERSING PUMPSET)
-BATTERY
COMMON
VR2
BASIC SYSTEM COMPONENTS
OPTIONAL ACCESSORIES
**MAKE SURE POWER IS TURNED OFF TO THE PILOT
SYSTEM PRIOR TO CHANGING DIP SWITCHES.
VR6 - FACTORY SET - DO NOT ADJUST
BYPASS
VALVE
JOG
STEERING
RUDDER ANGLE
INDICATOR
22
S2
1
+BATTERY
23
16
+
17
GND
18
+
19
-
20
S1
21
COM
RUDDER FOLLOWER
& LINKAGE
CONTROL
HEAD
CONTROL
HEAD
FLUXGATE
COMPASS
NMEA
INPUT
(GPS)
BATTERY HYDRAULIC
PUMPSET
CONTROL
HEAD
NMEA
OUTPUT
12
BLACK BLACK
GREEN
WHITE
RED
WHITE
VR4 VR1
24 12
(SOLENOID2)
(SOLENOID1)
15 AMP FUSE
VR6
12
DIP
SWITCHES **
3
5
MOTOR2
7
WHITE
8
SHIELD
9101112
DATA
13
GND
14
DATA
15
GND
4
MOTOR1
FOR COMNAV
RUDDER FOLLOWER
INSTALLATION
(SEE SECTION 2.5)
VR3
5 AMP FUSE
1
GREEN
2
YELLOW
3
WHITE
4
SHIELD
5
GREEN
6
YELLOW
1.3"
0.3"
1.2"
6.5"
2.2"
4.3"
4.75"
3
2
1
24 12
DIP SWITCHES
21
A-1510 DISTRIBUTION UNIT TEMPLATE
UP
DOWN
SHIELD

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2.2.1 Distribution Unit Connections
Distribution Unit connections should be according to the System Wiring Diagram
provided and in addition, the following points:
2.2.2 Safety Switch
Important! An external safety switch or circuit breaker (not supplied) should be
installed in line with power input. Make sure it is rated greater than or equal to 25
Amps.
This switch will serve as your Autopilot ultimate safety OFF switch.
2.2.3 DIP Switches
The main circuit board has 2 DIP Switches, which must be pre-set during
installation to suit the installed configuration.
Important! With power turned off to the system, do the following:
a) Locate DIP Switch for 12 or 24/32 VDC voltage and make sure it is set to the
voltage supply connected.
b) Locate DIP Switch for ”Solenoid Valve” or ”Pumpset” and make sure it is set to
the type of drive you have installed.
2.2.4 Trim Potentiometers
If an external Rudder Angle Indicator is fitted to a 1500 Distribution Unit, it can be
calibrated with the 2 trim potentiometers as indicated on drawing. Adjust VR3
labeled offset, for rudder center and VR2 labeled gain, for maximum deflection.
Note that this is just to calibrate an external Rudder Angle Indicator Instrument. The
NX2 instruments must be calibrated by changing the rudder angle transmitter arm
length.

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GROUND
SYMBOL
SILICONE GREASE
2.3 Control Head
Location
The Control Head is waterproof when gasket mounted to a flat surface. It should be
mounted near the steering position for ease of visibility and transfer from manual to
automatic.
Installation
Place the adhesive drill template on the desired location for the Control Head. Drill
the 2 holes using a 5mm (1/4") drill for the two pin bolts. Use a 63mm (2½") hole
saw to machine the clearance hole for the Control Head connection socket.
Remove the template.
•Screw the two pinbolts to the instrument.
•Put the instrument in place.
•Screw the two nuts from the back.
Note! The two nuts should only be hand tightened. Do not use a wrench.
•Run the NX2 Network cable from the Distribution Unit
to the Autopilot Instrument Control Head. Connect to
terminals #1, 2, 3 and 4 (see System Wiring
Diagram).
•If you want to cut the NX2 Network cable to length,
disconnect 4-pole jack plug and cut the cable. Peel
off about 35 mm (1,4") of the cable insulation.
Remove about 6 mm (1/4") from the 3 isolated wires
(the 4th wire is an earth / screen).
Attach the 4 cable protectors to the wires using a pair
of flat pliers.
•Connect the 4 cable protectors to the 4-pole jack plug
as shown.
•Apply silicon grease on all locations as shown.
This must be done to avoid corrosion.

ComNav 1500 / 1510 Autopilot - 12 -
•Apply silicon paste to the instrument connection pins at the back of the
Instrument. Press the jack plug onto the instrument pins. Press the cable in to the
cable leads.
•Secure the back cover with the screw.
All NX2 instruments are connected directly to the NX2 Network in a daisy chain.
They all use the same colour coded 4-pole jack plugs.

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2.4 Flux Gate Compass
Location
Compass location is most critical. This compass operates with an automatic
deviation feature. Best performance will be obtained if mounted at the center of
pitch and roll, in order to minimize undesirable accelerate which can degrade
compass stability. On most vessels this would be about 1/3 forward, on the
centerline and approximately at sea level. Various obstructions or magnetic
interference may exist at this ideal location and a reasonable compromise is
acceptable in establishing the exact location. The fore-aft arrow on the compass
should face forward and parallel to the boat centerline. If this is not possible, the
compass error resulting (lubber line error) may be corrected after Autodeviation has
been performed. The compass should be mounted with the cable outlet at the
bottom (See diagram on following page).
The following safe magnetic distances should be maintained where possible:
OBJECT SAFE DISTANCE
Ft. m.
Main Engine 7 2
Radar Magnetrons 5 1.5
Horizontal and Vertical Steel Plates, Tanks 3 1
High Power Electric Motors (bilge pumps,
refrigerators)
31
HF or VHF Antennas 10 3
High Current DC wires 3 1
Magnetic meter movements and loud speakers 3 1
Large bolts or fasteners 2 0.6
The above may not always be possible to maintain due to problems unique to each
vessel. If in doubt, check for local magnetic disturbance using the Installation
procedure.
Steel vessels are a special case and an experienced compass adjuster should be
consulted since the automatic compass compensation only corrects for horizontal
errors and significant deviation from vertical fields such as Vertical Heeling Error
can occur.