COURSEMASTER CM400N User manual

COURSEMASTER
AUTOPILOTS
A
ustralia's world leader in autopilot technolo
gy
CM400N OWNER'S MANUAL
COURSEMASTER AUTOPILOTS PTY LTD.
CHATSWOOD NSW. AUSTRALIA 2067
ACN 001 306 369
Phone [phone]
Fax [phone]
E-mail: [email protected]

CM400N OWNER'S MANUAL
Your Coursemaster CM400N is engineered for accurate and
reliable steering. But remember that it cannot keep a lookout.
SAFE NAVIGATION IS ALWAYS YOUR
RESPONSIBILITY.
Copyright 1997 Coursemaster Autopilots Pty Ltd, 7 Smith St, CHATSWOOD
NSW 2067, AUSTRALIA
This manual, the mechanical and electronic design of the CM550 autopilot
system and its associated software are protected by copyright.
Unauthorised copying may result in prosecution.

CM400N QUICK REFERENCE
MAIN DISPLAYS
346 A:346
1 4
LA
AAAA
H:346 H:-01
9P:346
PPPP
STEERING MODE RUDDER FACTOR
STANDBY PILOT
AUTONAV ON AUTONAV OK
RUDDER ANGLE
REMOTE HELM
AUTOTACK
PROGRAMMED COURSE
HOLD
PROGRAMMING MENU

CM400N QUICK REFERENCE
MENU AND ALARM DISPLAY
USE THE LEFT AND RIGHT DODGE KEYS TO ADJUST SETTINGS
- - - AHL -
A00 1: 01
A01 2:346
A02 3: 20
A03 4: 3
A04 5: 1
A05 6: 2
A08 7: 1
8: 1
9:013
- - - -
ALARMS MENU
AUTONAV FAULT
COLD START
OFF COURSE
HELM ALERT
DRIVE OVERLOAD
RUDDER OVERRANGE
COMPASS FAULT
SYSTEM FAULT
AUTO HELM SETUP
HELM ADJUST
COMPASS ADJUST
RUDDER LIMITS
AUTONAV MESSAGE
HELM DEADBAND
RATE FACTOR
AUTOTRIM
ALERT/ALARM
MAGNETIC VARIATION
COLD START

CM400N OWNER'S MANUAL
CONTENTS
1. SYSTEM DESCRIPTION
1.1 System components 1-1
1.2 The control panel 1-3
2. OPERATING INSTRUCTIONS
2.1 Basic operation 2-2
2.2 Operating Details 2-2
2.2.1 Steering modes 2-3
2.2.2 Rudder factor 2-4
2.2.3 Auto navigation 2-4
2.2.4 Remote (power) steering
2.2.5 Display select 2-4
2.2.6 Alarms and alarm override 2-5
2.3 Programming the system 2-7
Auto helm setup, Helm zero
Compass adjust, Rudder limits
Autonav messages, Helm deadband
Rate factor, Autotrim,
Helm and off-course alarms, Magnetic
Variation, Cold start.

3. ATTACHMENTS AND INTERFACES
3.1 Second Controller 3-1
3.2 Remote Steering 3-2
3.3 Rudder angle indicator 3-2
3.4 Remote Alarm 3-3
3.7 Navigation Interface 3-3
4. INSTALLATION
Step-by-step Summary 4-1
4.1 Junction Box 4-3
4.2 Controller 4-5
4.3 Compass 4-7
4.4 Rudder Transducer 4-8
4.5 Steering Drive 4-9
4.5.1 Chain driven mechanical 4-10
4.5.2 Solenoid-controlled hydraulics 4-11
4.5.3 System with Octopus pump 4-11
4.5.4 Hydraulic linear drive 4-17
5. TROUBLE-SHOOTING
5.1 Error messages 5-1
5.2 Other faults 5-4
6. SYSTEM SPECIFICATIONS 6-1
7. MAINTENANCE AND WARRANTY 7-1
SETUP RECORD
4n2man0 Rev 4-97

CHAPTER 1 SYSTEM DESCRIPTION
Your CM400N is an advanced autopilot, resulting from many years of
design and engineering experience at Coursemaster. The autopilot is simple to
use and we have also tried to keep this manual simple and staightforward. But
to obtain the best results, you should know how the pilot and your vessel will
work together. So please take some time to read this and please contact
Coursemaster or one of our agents if you have any questions.
The CM400N adds a number of features to its predecessor - the CM400.
These include a heavy-duty Junction Box, a wider range of input voltages, dual
Controller and Remote Helm capability, a remote alarm and, most importantly a
built-in interface to NMEA0183 navigation equipment.
1.1 SYSTEM COMPONENTS
The basic autopilot comprises:
CM641 Junction Box
CM400 Controller
CM416 Fluxgate compass
CM120 Rudder Transducer
CM151/CM1012 Steer Motor or Hydraulic Pump.

System Description 1-2
______________________________________________________________________
To these components may be added a range of options to expand the system
into one which will handle most autopilot needs. A block diagram of a CM400N
system with its optional attachments is shown in Fig 1.1.
At the centre of the system is the Junction Box, which houses the control
microcomputer, the interfaces with other system components and the motor
drive electronics. The controller is the input device both for normal system
useage and for all installation settings.
The compass is a fluxgate type and has an internally damped pendulum
suspension which accommodates a wide range of pitch and roll. It has been
proved reliable and accurate in thousands of existing Coursemaster systems.
For best results, there are certain rules for mounting it on the vessel. These are
explained in Chapter 4.
The rudder transducer and the various steer drive options have similarly
been developed and refined through earlier Coursemaster systems. The choice
and installation of the drive is also described in Chapter 4.
JUNCTION BOX
NMEA 0183
NAV SYSTEM
CM 641
SECOND
CONTROLLER
CM 416
FLUXGATE
CM 554/555
REMOTE
CONTROL
12/24 V
POWER
STEER
MOTOR CM 120
RUDDER TX
CM 630 RUDDER METER
REMOTE
ALARM
CM400
CM400 CONTROLLER
Figure 1.1 System Configuration, showing standard and
optional attachments.

System Description 1-3
______________________________________________________________________
1.2 THE CONTROL PANEL
The front panel of the controller (Fig 1.2) contains a 4 character display,
course error lamps and six keys. Most of the time, only the two keys on the left
are used. Chapter 2 contains full information on their use.
STBY
PILOT
PORT STBD
216
HEADING
PRESS
BOTH
KEYS
FOR OFF
SELECT
MODE
A:
DISPLAY CODE
COUSERMASTER 400
ON
SELECT
COURSE
DISPLAY
SELECT
OR
PROGRAM
COURSE ADJUST
Figure 1.2 Control Panel Layout
KEY FUNCTIONS
STANDBY
This switches the system on. When operating in any mode, this key returns the
system to STANDBY and switches the steering drive off. The key also cancels
alarms.
PILOT
Pressing this engages the autopilot and locks the vessel onto the current
heading
SWITCHING OFF
Pressing STANDBY and PILOT together turns the system OFF.

System Description 1-4
______________________________________________________________________
COURSE LEFT and RIGHT
Used to make course adjustments when in PILOT or to adjust system settings,
eg. rudder factor.
SELECT UP and DOWN
Used to change the sea-state setting, to display rudder angle or programmed
course, and to select system settings for adjustment.
Use of these keys is illustrated in the Quick Reference chart at the beginning of
this manual.
DISPLAY
In normal operation, the display shows the current magnetic heading, but can
be switched to show other information.
ERROR LAMPS
The course error lamps are operational for all modes of the system and
switch on for course errors greater than +/- 8.4 deg.
ALARMS
The alarm gives a single short beep when a key is pressed. Other alarm
patterns are accompanied by a message which identifies the problem. (See
Chap 2.) Examples include OFF COURSE (Code A01), which indicates that the
system has been off course for more than 12 sec and is in PILOT. HELM
ALERT (Code A02) comes up each 5 minutes to check that the helmsman is in
attendance when the system is in PILOT. Both of these alarms are cleared by
the STANDBY or PILOT key and the HELM ALERT may be disabled.
If a fault in the main processor or the link beteen the controller and the
junction box, the SYSTEM FAULT code, A08, together with an alarm pattern will
appear. If this occurs, SWITCH THE SYSTEM OFF.
4n2man1

CHAPTER 2 OPERATING INSTRUCTIONS
The CM400N is designed to be easy to use. The basic operations of
the autopilot are simple to carry out and involve single keystrokes on the panel.
These are described in the first section below. Then there are operations which
require several keystrokes and would be used only from time to time. These are
described next. Finally, there is a range of programming options, which are used to
adjust the pilot to special requirements. Some of these are used during
installation. Otherwise, it should be found that the factory settings of these
adjustments are suitable and that the programming operations are not needed.
Before using the pilot for the first time though, it is IMPORTANT that the
installation proceedures decribed in Chapter 4 have been carried out fully -
otherwise components of the system may be damaged.

Operating Instructions 2-2
________________________________________________________________
2.1 BASIC OPERATION
(a) To turn the system ON, press STANDBY. Wait for the display to show
the software version number (eg. P:214). The self-test is then complete
and the normal STANDBY display will appear.
(b) To turn the system OFF, hold the STANDBY and PILOT keys down
together.
(c) For normal autopilot operation, steer the vessel to the desired heading
and press PILOT. The autopilot will now lock onto that heading and
maintain it.
(d) To adjust the current heading, use the COURSE keys below the display.
Pressing a key briefly will trim the course port or starboard by 1 degree.
Holding the key down produces a continuous change up to 30 degrees.
The display shows the programmed course for a few seconds when the
COURSE keys are pressed.
(e) AUTOTACK: For sailing vessels, there is an option to produce a
delayed 100 deg course change to port or starboard. Press both course
keys together. A 9 will appear at the right of the display. Press one of
the course keys for the direction of the tack. The display will start
counting down from 9. After 8 seconds, the vessel will change course to
the new setting.
(f) To engage auto navigation (from a GPS receiver), press SELECT
DOWN once and then the COURSE RIGHT key. (See Sec 2.2.3)

Operating Instructions 2-3
________________________________________________________________
2.2 OPERATING DETAILS
The Quick Reference chart at the front of this manual gives a simple
graphical description of the following adjustments and messages.
2.2.1 STEERING MODES
The CM400N has two different types of steering modes to suit a variety
of vessels and weather conditions. One of these would be used most of the time,
but changing modes is done simply by pressing the SELECT UP key once and the
display then shows the steering mode on the left and the rudder factor on the right.
The steering mode is changed by pressing one of the SELECT keys again. After a
few seconds, the display will return to its normal format. The two modes are:
MODE 1 A direct, almost proportional control,without averaging. It
suits medium or small vessels in smooth or choppy
conditions and will give reasonable control in all vessels.
MODE 2 A counter rudder mode which applies a correction
according to both the error and the rate of turn. When
turning towards a course, reverse helm is applied before the
course is reached, in order to cancel the turning momentum.
MODE 2 is best suited to heavy vessels which are slow to
respond to helm corrections. Other vessels in a following
sea may also respond well in this mode.

Operating Instructions 2-4
________________________________________________________________
2.2.2 RUDDER FACTOR
For either mode, the amount of helm applied for a given course error is
separately adjustable. This RUDDER FACTOR can range from 0 to 9 (though 0
gives no control) and is set by pressing the SELECT UP key, followed by one of
the COURSE keys to adjust it up or down. A separate rudder factor is stored for
each mode.
2.2.3 AUTO NAVIGATION
If an NMEA0183 GPS or other navigation system is attached, the first
step in selecting it is to press the SELECT DOWN key once. The display will show
a single L (for local). Press the COURSE RIGHT key and the display changes to A.
Ten seconds or so later, when a valid message has been received, the display
changes to AAAA and you may return to the normal display by pressing the
SELECT UP key. During operation, if a valid message ceases to be received
during a 30 second period, the pilot will continue steering to the last valid
information received but the displays will be replaced by a row of dashes.
To cancel the autonav mode, press SELECT DOWN again, followed by
one of the COURSE keys. While AUTONAV is active, the pilot may still be
engaged or disengaged via the PILOT and STANDBY keys.
2.2.4 REMOTE (POWER) STEERING
A variety of remote steering attachments may be fitted - see Chapter 3.
When they are switched into the STANDBY or PILOT positions, the autopilot is
switched accordingly. But the STANDBY and PILOT keys on the Controller will

Operating Instructions 2-5
________________________________________________________________
override the remote unit. But if the remote unit is switched to REMOTE, it takes
control and adjusts the helm angle directly. In this condition, the main display
shows the current heading, preceeded by a flashing H symbol.
2.2.5 DISPLAY SELECT
The first press of SELECT DOWN displays the autonav option
described above. The second shows the helm angle in degrees (a minus sign
indicates port). The third press shows the programmed course. If autonav is in
use and a valid cross-track error message is received, this display alternates
between the reference course and the magnitude of the cross-track error. The
fourth selection is for system programming (see Sec 2.3).
2.2.6 ALARMS
The CM400N has several alarm functions. When an alarm occurs, the
beeper sounds and an alarm code appears. These are summarised in the Quick
Reference Chart and are explained below:
WAITING FOR DATA-THREE DASHES
This alarm is the most common and is the only one for which
the beeper does not sound. It occurs when switching to a
function that uses NMEA data. Normally, it will cancel itself
after a few seconds, but if it does not, refer to Chap 3.
COLD START - A00
This is to indicate that the built-in memory has been reset to
the factory settings and occurs after a COLD START.

Operating Instructions 2-6
________________________________________________________________
OFF COURSE - A01
The vessel has been more than 8 deg off course for 12
seconds. This only operates in the PILOT mode and while
the alarm is active, all other functions operate normally.
Cancel it by returning to course or pressing the STANBY or
PILOT key. It may be disabled by programming.
HELM ALERT - A02
In PILOT mode, this sounds each 5 minutes (or longer) as a
safety feature to ensure that the wheel is attended. It is
cancelled by the PILOT or STANDBY key and may be
changed by programming.
DRIVE OVERLOAD - A03
The current drawn by the steering gear has exceeded the
limits and the drive has been turned off. See Chap. 5 for
further information.
RUDDER OVERRANGE - A04
The rudder has travelled past its preset limits and the drive
has been turned off. This could indicate a mechanical or
electrical problem with the transducer. (See Chap.5). The
limits in STANDBY and REMOTE are fixed at 60 deg., while
the PILOT limits are at 30deg.
COMPASS FAULT - A05

Operating Instructions 2-7
________________________________________________________________
The magnetic field being sensed by the compass is above or
below preset limits and the system has been switched to
STANDBY. Again, further information is given in Chap. 5.
SYSTEM FAULT - A08
The Controller has detected a fault in the data coming from
the Junction Box. The autopilot should be switched off.
ALARM OVERRIDE
When an alarm appears, it can be useful to clear it temporarily from the
display so that other display options can be used to investigate the reason for the
alarm. To do this, hold the STANDBY key down for 3 seconds. The display will
return to normal, but the course error lamp will flash to indicate the presence of the
alarm. All functions will now operate, except that the system cannot be switched
into the pilot mode. To return to normal, switch off and restart the system.
2.3 PROGRAMMING THE SYSTEM
Hold the SELECT DOWN key for more than 2 seconds. The display will
read PPPP to indicate that it is changing to the program mode. Release the key
and the display will change to the first of the following options. You may scroll
through the options using the SELECT keys, or exit the program mode by pressing
STANDBY.
AHL AUTOMATIC HELM SETUP
This feature sets the correct phasing for the Rudder Transducer and
Steering Drive automatically. With the AHL prompt showing, turn the steering, by
hand, so that about 10 deg. of starboard helm is applied. Press the COURSE

Operating Instructions 2-8
________________________________________________________________
RIGHT key and the setup will start, returning the helm to the centre position. If
there is a fault in the steering gear, the alarm A06 will show on the display,
otherwise the system will return to STANDBY. To adjust any of the following, re-
select the program mode and select up or down.
HELM ZERO - 1
For best overall performance, it is recommended that the displayed rudder angle
be adjusted to read zero when the helm is dead ahead. This adjustment
compensates for errors in the transducer linkage and other offsets in the steering
gear. The current helm angle is displayed and should read 00 at the centre. Use
the COURSE LEFT or RIGHT keys to trim the reading.
COMPASS ADJUST - 2
The current fluxgate heading is displayed and zero errors may be
compensated using the COURSE keys.
RUDDER LIMITS - 3
The maximum rudder angle is preset to 20 degrees in pilot this limit may
be changed from 20 deg., using the COURSE keys, though such a change is
usually unneccessary. The limits for remote steering are preset in the remote
control.
AUTONAV MESSAGE - 4
A group of one of the more common NMEA messages may be selected
for use in the autonav mode. Use the COURSE keys to select a number from the
following:

Operating Instructions 2-9
________________________________________________________________
0 RMB - Composite true heading to steer and
cross-track error.
1 BWW or BOD -Magnetic heading to steer.
2 XTE Cross-track error (only).
3 APA or APB - Magnetic heading to steer
plus cross-track error.
4-9 Disabled.
Newer models of GPS receivers produce the RMB sentence, which is
recommended. Since this contains a TRUE heading-to-steer, the magnetic
variation must be set. (Option 9). The APA/APB sentence is produced by most of
the earlier receivers and may also be used. The CM400N detects whether this
sentence uses a true or magnetic heading and adjusts automatically using the
variation set by the user. If XTE is chosen, the pilot steers to a reference course
set by pressing STANDBY or PILOT in the normal way and the cross-track error
signal modifies the course around that setting.
HELM DEADBAND - 5
The deadband acts as a filter which prevents the steering drive from
pulsing on and off in response to very small error signals. If it is set too high, the
steering will be slow to respond to small corrections. The best setting is one just
above the value which produces continuous pulsing of the steering gear.
RATE FACTOR - 6
If Mode 2 is used, the strength of the counter rudder action may be
varied with this factor. The preset value of 2 is generally suitable, but a value of 1
may be better for high-speed vessels. Slow vessels with a tendency to a steering
overshoot may be better with a setting of 3 to 4.
AUTOTRIM - 7

Operating Instructions 2-10
________________________________________________________________
The CM400 incorporates an automatic trim feature which compensates
for weather helm or other sources of steering bias (such as when towing). This
means that, after a few minutes on a given course, the autopilot calculates how
much weather helm to apply so that it centres itself accurately on the programmed
course. If the display reads 7: 1, autotrim is ON. It may be disabled by using the
COURSE keys to set this to 0.